Numerical Investigation of Subcooled Boiling Flow and Patterns’ Transitions in a High-Heat-Flux Rectangular Small Channel

The escalating thermal demands of high-power electronic devices and energy systems necessitate advanced thermal management solutions. Flow boiling in small/micro channels has emerged as a promising approach, yet its practical implementation is hindered by flow instabilities and heat transfer deterioration under high-heat fluxes. This study presents a systematic numerical investigation of subcooled boiling flow and heat transfer in a rectangular small channel under high-heat-flux conditions, employing the VOF method coupled with the Lee phase change model. The increasing heat flux accelerates bubble nucleation and coalescence while reduced mass flux promotes early local slug formation, shifting flow transitions upstream and degrading thermal performance. A local vapor volume fraction threshold of αν = 0.2 is identified for the bubbly-to-sweeping flow transition and αν = 0.4 for the sweeping-to-churn transition. Furthermore, a novel dimensionless parameter β is proposed to classify dominant flow regimes, with critical β ranges of 12–16 and 24–32 corresponding to the two transitions, respectively. These findings provide new quantitative tools for identifying flow regimes and improve the understanding and design of compact boiling-based thermal management systems under extreme heat- flux conditions.