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Physics-Based Conjugate Heat Transfer Refinement for Microlayer Sub-Grid Model and X-ray-Informed Transition-Angle Modeling for Single-Bubble Nucleate Boiling Simulations
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DOI：10.1016/j.net.2026.104538.png)
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Abstract
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Accurate prediction of nucleate boiling heat transfer remains challenging due to the multiscale interactions among microlayer evaporation, conjugate heat transfer, and near-wall interfacial dynamics. In the present study, a physics-based and computationally efficient conjugate heat transfer refinement for the microlayer subgrid model is developed to simulate single-bubble nucleate boiling. A transition-angle concept, derived from synchrotron X-ray imaging, is introduced to reconstruct the transition region between the microlayer and the bulk liquid beneath a growing bubble. The model is implemented within a CLSVOF framework and validated against X-ray experimental data. The results show that the transition-angle model improves predictions of bubble growth and transition-region geometry compared with simulations based on the apparent contact angle. Energy balance analysis confirms that the model accurately captures the coupling between wall heat transfer and microlayer evaporation. Heat-transfer analysis demonstrates that the microlayer, transition, and bulk regions contribute approximately 55%, 20%, and 25% of the total bubble heat transfer, respectively, under the wall superheat condition of 20K. The predicted transition-region contribution agrees closely with experimental measurements, whereas conventional simulations based on the apparent contact angle will significantly underestimate it. The proposed approach provides a more physically consistent framework for predicting the partitioning of wall heat transfer in nucleate boiling.
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