High-pressure steam pipes inevitably suffered from the reciprocal interaction of high pressure and temperature during a long-period service, causing deformation and cracking. However, only limited studies about abnormal bulging caused by condensed water have been carried out. To study the relationship between bulging and condensed water, bulging tee joints belonging to high-pressure steam pipes were investigated with a macro visual inspection, chemical composition analysis, and metallographic microscopy. According to the analysis of the bulging samples, pearlite spheroidization was found in the abnormal bulging tee joint. The ANSYS FLUENT modeling indicated that the tube wall of bulging tees was continuously subjected to alternating stress, causing the cyclic transformation of the liquid–gas phase inside the tee joint. The results indicate that the stress produced by a condensed water droplet ranges from 532.8 MPa to 59 MPa, continuously exerting pressure on the tube wall of the tee joint. When combined with the variation in the temperature field, the temperature of the severe bulging tee joint and slight bulging tee joint alternates. Further modeling illustrates that the stress generated by the impact of condensed water droplets on the high-temperature tee joints causes a ratcheting effect, which is identified as the main factor contributing to the bulging of the tee joint. Deterioration of the microstructure is considered a secondary mechanism.

The critical heat flux (CHF) of minichannel heat sinks is crucial, as it helps prevent thermal safety incidents and equipment failure. However, the underlying mechanisms of CHF in minichannels remain poorly understood, and existing CHF prediction models require further refinement. This study systematically investigates the characteristics and influencing factors of critical heat flux (CHF) in rectangular minichannels through combined experimental and theoretical approaches. Experiments were conducted using microchannels with hydraulic diameters ranging from 0.5 to 2.0 mm, with ethanol employed as the working fluid. Key parameters-including mass flux, channel geometry, system pressure, and inlet subcooling-were analyzed to assess their influence on CHF. Results indicate that CHF increases with mass flux; however, the increase rate diminishes under higher mass flux. Larger channel dimensions significantly enhance CHF by delaying liquid film dryout. System pressure further improves CHF by reducing bubble detachment frequency and promoting flow stability. Increased inlet subcooling enhances CHF by delaying the onset of nucleate boiling and improving convective heat transfer. Four classical CHF prediction models were evaluated, revealing significant overprediction-up to 148.69% mean absolute error (MAE)-particularly for channels with hydraulic diameters below 1.0 mm. An ANN deep learning model was developed, achieving a reduced MAE of 8.93%, with 93% of predictions falling within ±15% error. This study offers valuable insights and a robust predictive model for optimizing microchannel heat sink performance in high heat flux applications.