Surface roughness significantly modifies the liquid film thickness entrained when dip coating a solid surface, particularly at low coating velocity. Using a homogenization approach, we present a predictive model for determining the liquid film thickness coated on a rough plate. A homogenized boundary condition at an equivalent flat surface is used to model the rough boundary, accounting for both flow through the rough texture layer, through an interface permeability term, and slip at the equivalent surface. While the slip term accounts for tangential velocity induced by viscous shear stress, accurately predicting the film thickness requires the interface permeability term to account for additional tangential flow driven by pressure gradients along the interface. We find that a greater degree of slip and interface permeability signifies less viscous stress that would promote deposition, thus reducing the amount of free film coated above the textures. The model is found to be in good agreement with experimental measurements, and requires no fitting parameters. Furthermore, our model may be applied to arbitrary periodic roughness patterns, opening the door to flexible characterization of surfaces found in natural and industrial coating processes.

This study explores the application of a wall-attached ferrofluid film to decrease skin-friction drag in turbulent channel flow. We conduct experiments using water as a working fluid in a turbulent channel flow set-up, where one wall is coated with a ferrofluid layer held in place by external permanent magnets. Depending on the flow conditions, the interface between the two fluids is observed to form unstable travelling waves. While ferrofluid coating has been previously employed in laminar and moderately turbulent flows (Reynolds number $Re<4000$) to reduce drag by creating a slip condition at the fluid interface, its effectiveness in fully developed turbulent conditions, particularly when the interface exhibits instability, remains uncertain. Our primary objective is to assess the effectiveness of ferrofluid coating in reducing turbulent drag with particular focus on scenarios when the ferrofluid layer forms unstable waves. To achieve this, we measure flow velocity using two-dimensional particle tracking velocimetry (2D-PTV), and the interface contour between the fluids is determined using an interface tracking algorithm. Our results reveal the significant potential of ferrofluid coating for drag reduction, even in scenarios where the interface between the surrounding fluid and ferrofluid exhibits instability, with observed drag reduction rates up to 95 %. In particular, waves with an amplitude significantly smaller than a viscous length scale positively contribute to drag reduction, while larger waves are detrimental, because of induced turbulent fluctuations. However, for the latter case, slip outcompetes the extra turbulence so that drag is still reduced.

To investigate the influence of inertia and slip on the instability of a liquid film on a fibre, a theoretical framework based on the axisymmetric Navier–Stokes equations is proposed via linear instability analysis. The model reveals that slip significantly enhances perturbation growth in viscous film flows, whereas it exerts minimal influence on flows dominated by inertia. Moreover, under no-slip boundary conditions, the dominant instability mode of thin films remains unaltered by inertia, closely aligning with predictions from a no-slip lubrication model. Conversely, when slip is introduced, the dominant wavenumber experiences a noticeable reduction as inertia decreases. This trend is captured by an introduced lubrication model with giant slip. Direct numerical simulations of the Navier–Stokes equations are then performed to further confirm the theoretical findings at the linear stage. For the nonlinear dynamics, no-slip simulations show complex vortical structures within films, driven by fluid inertia near surfaces. Additionally, in scenarios with weak inertia, a reduction in the volume of satellite droplets is observed due to slip, following a power-law relationship.

Gravure printing is a type of printing method that uses metal cylinders with engraved cells that hold ink. The ink is transferred directly to the paper or other material by pressing it against the cylinder. The flow associated with gravure printing includes a flow in a liquid bridge formed in the contact region of the cylinders and a thin-film coating flow of the ink. The flow is governed by viscous and capillary forces. In many cases, the flow is unstable, which leads to the formation of instability patterns on the printed surfaces. The analysis of these instabilities is a very challenging problem, especially since industrial inks are usually rheologically complex. In this experimental and theoretical study, the flow of inks on a rotating cylinder is analysed, accounting for the shear-rate-dependent liquid viscosity. A theoretical solution for the film flow allows us to predict the width of the liquid bridge between two cylinders. Moreover, it is shown that the measured characteristic size of the printed pattern is of the same order as the predicted liquid bridge width. We observe a nearly linear dependence of pattern size and liquid bridge width.

The coefficient of friction of clay minerals at the micro-scale has generally not been studied due to difficulties in obtaining measurements in a bulk-soil volume undergoing shear at such small scales. Information on friction at the micro-scale may provide insight into grain-scale processes that operate in bulk samples or in natural faults. The objective of this study was to develop a method to measure the microscale friction coefficient of smectites. The experiments described show that the axial atomic force microscopy method can be adapted to easily obtain accurate coefficient of friction (μ) measurements for smectites from force curves involving colloidal probes. The method allows for the measurements to be performed over spatial scales of a few μm, can be carried out under dry conditions or a wide range of aqueous solutions, and requires no calibration beyond making a few microscopic measurements of the probe. This method provides measurements of micro-scale normal and shear forces between minerals, which can be used for a variety of applications such as the study of shear deformation, consolidation, and fault dynamics. Control tests of silica on mica (μ = 0.29±0.02) agree with literature values where limits indicate one standard deviation. Coefficient of friction values for wet and dry Na-montmorillonite were determined to be 0.20±0.03 and 0.72±0.03, respectively.

A theoretical and experimental investigation of two-dimensional (2-D) liquid curtains (gravitationally thinning liquid sheets) is provided under conditions where the curtain issues from a thin slot whose centreline is inclined with respect to the vertical. This analysis is motivated in part by recent works where it has been proposed that oblique liquid curtains (those exiting a non-vertical slot) may bend upwards against gravity when the relevant Weber number at the slot is less than unity ($We <1$). By contrast, Weinstein et al. (J. Fluid Mech., vol. 876, 2019, R3) have proposed that such $We<1$ curtains must be vertical and downward falling regardless of the inclination of the slot. Under low-Reynolds-number ($Re$) conditions typical of liquid film coating operations, our experiments show that the curtain shape follows the classic ballistic (parabolic) trajectory in the supercritical regime ($We>1$). In subcritical conditions ($We<1$), experiments show that the downward-falling curtain is vertical except in a relatively small region near the slot, where the combined effects of viscosity and surface tension induce the so-called teapot effect. These experimental results are confirmed by 2-D numerical simulations, which predict the curtain behaviour ranging from highly viscous ($Re = O(1)$) to nearly inviscid conditions. The one-dimensional (1-D) inviscid model of Weinstein et al. is recast in a different form to facilitate comparisons with the 2-D model, and 1-D and 2-D results agree favourably for supercritical and subcritical conditions. Despite the large parameter range explored, we have found no evidence that upward-bending curtains exist in an oblique configuration.

It is known that the disintegration of vertical liquid curtains (sheets) is affected crucially by the amplification of free edge holes forming inside the curtain. This paper aims to investigate the influence of the hole expansion dynamics, driven by the so-called rim retraction, on the breakup of a liquid curtain, in both supercritical (Weber number $We > 1$) and subcritical ($We < 1$) conditions. The analysis is based on three-dimensional direct numerical simulations. For a selected supercritical configuration, the steady flow topology is first analysed. The investigation reveals the classic triangular shape regime of the steady curtain, due to the surface-tension-induced borders retraction towards its centre plane. The unsteady dynamics is then investigated as the curtain response to a hole perturbation introduced artificially in the steady flow configuration. The hole evolution determines a rim retraction phenomenon inside the curtain, which is influenced by both capillary and gravity forces. In supercritical conditions, the hole does not influence the curtain flow dynamics in the long-time limit. By reducing the Weber number slightly under the critical threshold ($We=1$), the initial amplification rate of the hole area increases, due to the stronger retraction effect of surface tension acting on the hole rims. The free hole expansion in fully subcritical conditions ($We < 1$) is investigated finally by simulating an edge-free curtain flow. As $We$ decreases progressively, the hole expands while it is convected downstream by gravity acceleration. In the range $0.4< We<1$, the subcritical curtain returns to the intact unperturbed configuration after the hole expulsion at the downstream outflow. For $We<0.4$, the surface tension force becomes strong enough to reverse the gravitational motion of the hole top point, which retracts upstream towards the sheet inlet section while expanding along the lateral directions. This last phenomenon causes finally the breakup of the curtain, which results in a columnar regime strictly resembling similar experimental findings of the literature.

We study a gravity-driven viscous flow coating a vertical cylindrical fibre. The destabilisation of a draining liquid column into a downward moving train of beads has been linked to the conjunction of the Rayleigh–Plateau and Kapitza instabilities in the limit of small Bond numbers $Bo$. Here, we focus on quasi-inertialess flows (large Ohnesorge number $Oh$) and conduct a linear stability analysis on a unidirectional flow along a rigid eccentric fibre for intermediate to large $Bo$. We show the existence of two unstable modes, namely pearl and whirl modes. The pearl mode depicts asymmetric beads, similar to that of the Rayleigh–Plateau instability, whereas a single helix forms along the axis in the whirl mode instability. The geometric and hydrodynamic thresholds of the whirl mode instability are investigated, and phase diagrams showing the transition thresholds between different regimes are presented. Additionally, an energy analysis is carried out to elucidate the whirl formation mechanism. This analysis reveals that despite the unfavourable capillary energy cost, the asymmetric interface shear distribution, caused by the fibre eccentricity, has the potential to sustain a whirling interface. In general, small fibre radius and large eccentricity tend to foster the whirl mode instability, while reducing $Bo$ tends to favour the dominance of the pearl mode instability. Finally, we compare the predictions of our model with the results of some illustrative experiments, using highly viscous silicone oils flowing down fibres. Whirling structures are observed for the first time, and the measured wavenumbers match our stability analysis prediction.

We carried out experimental and numerical investigations on the axisymmetric spreading evolution of dynamic spin coating with a single drop of ethanol. The results show that the dynamic spreading process consists of two stages: inertial spreading stage and centrifugal thinning stage. These two stages are connected by a transient state in between characterized by the minimum contact line moving velocity. The Weber number determines the spreading in the first stage, similar to the case of the impact of a drop on a static substrate. The rotational Bond number has a marginal effect on the inertia spreading and the radius at the transient state. In the centrifugal thinning stage, the rotational Bond number dominates the flow while the effect of the Weber number is negligible.

This paper addresses several aspects of the axisymmetric flow of a liquid film over the surface of a downward-sloping cone. The study is rooted on a validated computational tool the results of which are interpreted with the help of a hyperbolic time-dependent reduced-order model also derived in the paper. The steady version of the model demonstrates the weakening and ultimate disappearance of the circular hydraulic jump as the cone surface transitions from planar to downward sloping. Mathematically, this evolution is reflected in a change of the model's critical point from spiral to node. A significant advantage of the time-dependent model is that, when it is integrated in time, the flow regions upstream and downstream of the critical point are connected. Due to this feature, when a hydraulic jump exists, its position can be sharply captured automatically with a good agreement with Navier–Stokes simulations. Surface-tension effects are properly accounted for and, in steady conditions, are shown to have a marginal effect on the flow, including the position of the hydraulic jump. A correlation is obtained for the jump radius as a function of the flow rate, liquid viscosity, gravitational acceleration and the angle of inclination of the cone surface. In a suitable limit, the model reduces to the optimal two-dimensional, first-order model for liquid film flow down an inclined plane and, in a different limit, it describes an axisymmetric thin liquid film falling down the surface of a vertical cylinder. Some results are also presented for the waves induced by a pulsating jet on the surface of the liquid film and for a jet impinging on the surface of a cone from below.

Various coatings in high-power laser facilities suffer from laser damage due to nodule defects. We propose a nodule dome removal (NDR) strategy to eliminate unwanted localized electric-field (E-field) enhancement caused by nodule defects, thereby improving the laser-induced damage threshold (LIDT) of laser coatings. It is theoretically demonstrated that the proposed NDR strategy can reduce the localized E-field enhancement of nodules in mirror coatings, polarizer coatings and beam splitter coatings. An ultraviolet (UV) mirror coating is experimentally demonstrated using the NDR strategy. The LIDT is improved to about 1.9 and 2.2 times for the UV mirror coating without artificial nodules and the UV mirror coating with artificial nodule seeds with a diameter of 1000 nm, respectively. The NDR strategy, applicable to coatings prepared by different deposition methods, improves the LIDT of laser coating without affecting other properties, such as the spectrum, stress and surface roughness, indicating its broad applicability in high-LIDT laser coatings.

The natural and forced dynamic response of a gravitational plane liquid sheet (curtain) of finite length interacting with an unconfined gaseous ambient is numerically and experimentally investigated. The global eigenvalue spectrum obtained by means of a linear inviscid one-dimensional model, accounting for the coupling between the curtain motion and the ambient pressure disturbances, clearly shows an abrupt increase (jump) in the characteristic natural frequency of the flow when the supercritical ($We>1$) to subcritical ($We<1$) transition occurs, with the Weber number $We$ defined as the ratio between inertia and capillary forces. On the other hand, the numerical simulation of the forced sheet response does not show any discontinuity between supercritical and subcritical conditions, as recently found by Torsey et al. (J. Fluid Mech., vol. 910, 2021, pp. 1–14) in the case of an infinite liquid sheet subjected to imposed ambient pressure disturbances not coupled with the curtain motion. It is argued that the forced liquid sheet behaviour varies continuously in shape and amplitude between the two regimes, not depending on the specific liquid–gas interaction model considered, whilst the natural frequency of the finite flow system does undergo a discontinuity, which can be theoretically predicted by the model of sheet–ambient interaction employed here. As a major result, the experimental evidence of the natural frequency jump is for the first time provided as well.

Dip coating consists of withdrawing a substrate from a bath to coat it with a thin liquid layer. This process is well understood for homogeneous fluids, but heterogeneities, such as particles dispersed in liquid, lead to more complex situations. Indeed, particles introduce a new length scale, their size, in addition to the thickness of the coating film. Recent studies have shown that, at first order, the thickness of the coating film for monodisperse particles can be captured by an effective capillary number based on the viscosity of the suspension, providing that the film is thicker than the particle diameter. However, suspensions involved in most practical applications are polydisperse, characterized by a wide range of particle sizes, introducing additional length scales. In this study, we investigate the dip coating of suspensions having a bimodal size distribution of particles. We show that the effective viscosity approach is still valid in the regime where the coating film is thicker than the diameter of the largest particles, although bidisperse suspensions are less viscous than monodisperse suspensions of the same solid fraction. We also characterize the intermediate regime that consists of a heterogeneous coating layer and where the composition of the film is different from the composition of the bath. A model to predict the probability of entraining the particles in the liquid film depending on their sizes is proposed and captures our measurements. In this regime, corresponding to a specific range of withdrawal velocities, capillarity filters the large particles out of the film.

Experiments are conducted to explore the rolling of a cylinder over a pool of viscous fluid. The speed, width and loading of the cylinder are varied along with the initial depth and length of the viscous pool. Depending on the conditions, the cylinder will either ride on a lubrication film or remain in solid contact with the underlying substrate. For the former situation, a lubrication theory is presented that describes the pressure underneath the cylinder and the thickness of the film. The theory approximates the flow by the one-dimensional Reynolds equation with the addition of one term, with an adjustable parameter, to account for the flux of fluid to the cylinder sides. Once this parameter is calibrated against experiment, the theory predicts peak lubrication pressures, gap sizes and film thicknesses to within approximately ten per cent. For lubricated rolling, the film splits evenly between the cylinder and substrate downstream of the nip. The printer's instability arises during the splitting process, patterning the residual fluid films on the substrate and cylinder. If the pool length is less than the cylinder circumference, the fluid adhering to the cylinder is rotated back into contact with the substrate, and when there is sufficient adhered fluid a lubrication film forms that can again be modelled by the theory. Conversely, if there is insufficient adhered fluid, no contiguous lubrication film is formed; instead, the pattern from the printer's instability ‘prints’ from the cylinder to the substrate.