Thermal-hydraulics modeling for prototype testing of the W7-X high heat flux scraper element

•Comparison of computational results to experimental measurements for W7-X PFCs.•Single-phase thermal hydraulics modeling performed to study manufacturing effects.•Studied effects of thermal contact resistance and potential CFC fiber misalignment.•Circumferential temperature distributions highlighted expected boiling regions.•Modest angles of CFC fiber misalignment can cause asymmetries at monoblock edges.