Liquid flowing down a fibre readily destabilises into a train of beads, commonly called a bead-on-fibre pattern. Bead formation results from capillary-driven instability and gives rise to patterns with constant velocity and time-invariant bead frequency $f$ whenever the instability is absolute. In this study, we develop a scaling law for $f$ that relates the Strouhal number $St$ and capillary number $Ca$ for Ostwaldian power-law liquids with Newtonian liquids recovered as a limiting case. We validate our proposed scaling law by comparing it with prior experimental data and new experimental data using xanthan gum solutions to produce a low capillary number $Ca \leq 10^{-2}$ regime. The experimental data encompasses both Ostwaldian and Newtonian flow, as well as symmetric and asymmetric patterns, and we find the data collapses along the predicted trend across seven orders of magnitude in $Ca$. Our proposed scaling law is a powerful tool for studying and applying bead-on-fibre flows where $f$ is critical, such as heat and mass transfer systems.

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.

We examine the gravity-driven flow of a thin film of viscous fluid spreading over a rigid plate that is lubricated by another viscous fluid. We model the flow over such a ‘soft’ substrate by applying the principles of lubrication theory, assuming that vertical shear provides the dominant resistance to the flow. We do so in axisymmetric and two-dimensional geometries in settings in which the flow is self-similar. Different flow regimes arise, depending on the values of four key dimensionless parameters. As the viscosity ratio varies, the behaviour of the intruding layer ranges from that of a thin coating film, which exerts negligible traction on the underlying layer, to a very viscous gravity current spreading over a low-viscosity, near-rigid layer. As the density difference between the two layers approaches zero, the nose of the intruding layer steepens, approaching a shock front in the equal-density limit. We characterise a frontal stress singularity, which forms near the nose of the intruding layer, by performing an asymptotic analysis in a small neighbourhood of the front. We find from our asymptotic analysis that unlike single-layer viscous gravity currents, which exhibit a cube-root frontal singularity, the nose of a viscous gravity current propagating over another viscous fluid instead exhibits a square-root singularity, to leading order. We also find that large differences in the densities between the two fluids give rise to flows similar to that of thin films of a single viscous fluid spreading over a rigid, yet mobile, substrate.

A long-wave asymptotic model is developed for a viscoelastic falling film along the inside of a tube; viscoelasticity is incorporated using an upper convected Maxwell model. The dynamics of the resulting model in the inertialess limit is determined by three parameters: Bond number Bo, Weissenberg number We and a film thickness parameter $a$. The free surface is unstable to long waves due to the Plateau–Rayleigh instability; linear stability analysis of the model equation quantifies the degree to which viscoelasticity increases both the rate and wavenumber of maximum growth of instability. Elasticity also affects the classification of instabilities as absolute or convective, with elasticity promoting absolute instability. Numerical solutions of the nonlinear evolution equation demonstrate that elasticity promotes plug formation by reducing the critical film thickness required for plugs to form. Turning points in travelling wave solution families may be used as a proxy for this critical thickness in the model. By continuation of these turning points, it is demonstrated that in contrast to Newtonian films in the inertialess limit, in which plug formation may be suppressed for a film of any thickness so long as the base flow is strong enough relative to surface tension, elasticity introduces a maximum critical thickness past which plug formation occurs regardless of the base flow strength. Attention is also paid to the trade-off of the competing effects introduced by increasing We (which increases growth rate and promotes plug formation) and increasing Bo (which decreases growth rate and inhibits plug formation) simultaneously.

A cylindrical liquid thread readily destabilizes into a series of drops due to capillary instability, which is also responsible for undesirable bead-on-fibre structures observed when coating a thin fibre. In this experimental study, we show how a falling liquid thread can be stabilized by internally distorting the cross-sectional shape using two vertically hung fibres. Below a critical flow rate $Q_c$, the dual-fibre system deforms the falling thread into a smooth column with a non-circular cross-section, thereby suppressing instability. Above $Q_{{c}}$, the cylindrical thread is left undeformed by the fibres and destabilizes into beads connected by a stable, non-cylindrical film. An empirical stability threshold is identified showing that flow delays the onset of capillary instability when compared with a marginally stable quasi-static coating. When the flow is unstable $Q>Q_c$, the bead velocity $v$ obeys a simple scaling law that is well supported by our experiments over a large parameter range. This suppression technique can be extended to other slender geometries, such as a ribbon, which shows similar qualitative results but exhibits a different stability threshold due to spontaneous dewetting about its short edge.

The stability of liquid-film flows is essential in many industrial applications. In the dip-coating process, a liquid film forms over a substrate extracted at a constant speed from a bath. We studied the linear stability of this film considering different thicknesses $\hat {h}$ for four liquids, spanning an extensive range of Kapitza numbers ($Ka$). By solving the Orr–Sommerfeld eigenvalue problem with the Chebyshev–Tau spectral method, we calculated the threshold between growing and decaying perturbations, investigated the instability mechanism, and computed the absolute/convective threshold. The instability mechanism was studied by analysing the perturbations’ vorticity distribution and the kinetic energy balance. It was found that liquids with low $Ka$ (e.g. corn oil, $Ka = 4$) are stable for a smaller range of wavenumbers compared with liquid with high $Ka$ (e.g. liquid zinc, $Ka = 11\,525$). Surface tension has a stabilising and a destabilising effect. For long waves, it curves the vorticity lines near the substrate, reducing the flow under the crests. For short waves, it fosters vorticity production at the interface and creates a region of intense vorticity near the substrate. In addition, we discovered that the surface tension contributes to both the production and dissipation of perturbation's energy depending on the $Ka$ number. Regarding the absolute/convective threshold, we identified a window in the parameter space where unstable waves propagate throughout the entire domain (indicating absolute instability). Perturbations affecting Derjaguin's solution ($\hat {h}=1$) for $Ka<17$ and the Landau–Levich–Derjaguin solution ($\hat {h}=0.945 Re^{1/9}Ka^{-1/6}$), are advected by the flow (indicating convective instability).

We present herein the derivation of a lubrication-mediated (LM) quasi-potential model for droplet rebounds off deep liquid baths, assuming the presence of a persistent dynamic air layer which acts as a lubricating pressure transfer. We then present numerical simulations of the LM model for axisymmetric rebounds of solid spheres and compare quantitatively to current results in the literature, including experimental data in the low-speed impact regime. In this regime the LM model has the advantage of being far more computationally tractable than direct numerical simulation (DNS) and is also able to provide detailed behaviour within the micro-metric thin lubrication region. The LM system has an interesting mathematical structure, with the lubrication layer providing a free-boundary elliptic problem mediating the drop and bath free-boundary evolutionary equations.

The motion of a bubble of negligible viscosity, such as air, forced down a tube filled with a viscous fluid which wets the walls of the tube has become a classic of the fluid dynamical literature. The differential motion of the bubble and the fluid are determined by the thin film which surrounds the bubble, whose shape and thickness are set by the interplay between gradients in surface tension and viscous shear stresses. Bretherton (J. Fluid Mech., vol. 10, issue 2, 1961, p. 166) provided a first, clear mathematical analysis in the lubrication limit coupled with carefully constructed experimental confirmation of the thin films deposited by a bubble moving in the confining geometry of the capillary tube. Its lasting impact has been not only in the migration of bubbles, but in a host of related fluid dynamical, industrial, biological and environmental processes for which thin lubricating films on the sometimes convoluted geometries of complex microstructures, such as porous media, determine the large-scale behaviour.

We present the results of a combined experimental and theoretical investigation of different fluid sheet structures formed during the impingement of a laminar liquid jet on a vial, with a slightly larger diameter than the jet and filled with the same liquid. The present set-up produces all diverse fluid sheet structures, unlike previous experiments that required a deflector disk resulting in no-slip and no-penetration boundary conditions. The water sheet structures are classified into four regimes; regime I: pre-sheet; regime II: puffing, characterized by the periodic formation and destruction of the upward-rising water sheet, an interesting observation not reported earlier; regime III, steady upward, inverted umbrella-like sheet structures; and regime IV, the formation of downward, umbrella-like sheet structures, which can be either open or closed, classically referred to as ‘water bells’. The water sheet structures observed are governed by the non-dimensional parameters: the ratio of vial diameter to the jet diameter at impact ($X$), the capillary number ($Ca$), the Weber number ($We$) and the Froude number ($Fr$). The parametric spaces $X-Ca$, $X-We$ and $X-Fr$ exhibit the demarcation of the four regimes. A semi-empirical expression for the ejection angle of the liquid sheet, primarily responsible for different shapes, is derived in a control volume that provides a theoretical basis for the identified regime diagrams. The puffing water bells in regime II are found to be quasi-steady as the experimental trajectories are in good agreement with the steady-state theory. The rise time of puffing water bells that determines the puffing frequency has been modelled.

Liquid droplet dynamics are widely used in biological and engineering applications, which contain complex interfacial instabilities and pattern formation such as droplet merging, splitting and transport. This paper studies a class of mean field control formulations for these droplet dynamics, which can be used to control and manipulate droplets in applications. We first formulate the droplet dynamics as gradient flows of free energies in modified optimal transport metrics with nonlinear mobilities. We then design an optimal control problem for these gradient flows. As an example, a lubrication equation for a thin volatile liquid film laden with an active suspension is developed, with control achieved through its activity field. Lastly, we apply the primal–dual hybrid gradient algorithm with high-order finite-element methods to simulate the proposed mean field control problems. Numerical examples, including droplet formation, bead-up/spreading, transport, and merging/splitting on a two-dimensional spatial domain, demonstrate the effectiveness of the proposed mean field control mechanism.

We study the stability and dewetting dynamics of a thin free-surface film composed of two miscible liquids placed on a solid substrate. Our study focuses on the development of a self-consistent model such that the mixture concentration influences both free-surface and wetting energies. By assuming a simple relation between these energies and the bulk and surface concentrations, we analyse their effect on the concentration distribution and dewetting down to the equilibrium film thickness determined by the fluid–solid interaction potential. The model, developed within the gradient dynamics formulation, includes the dependence of the free-surface energy on surface concentration leading to the Marangoni effect, while a composition-dependent Hamaker constant describes the wetting energy resulting from the fluid–solid interaction. We analyse the restrictions that must be fulfilled to ensure an equilibrium state for a flat film of a binary fluid. Then, we proceed by studying its linear stability. First, we consider the Marangoni effect while assuming that wetting energy depends only on the fluid thickness. Then, we include a dependence of wetting energy on concentration and study its effects. We find that the linear stability results compare very well with those of numerical simulations of the full nonlinear problem applied to the particular case of a binary melted metal alloy, even close to breakup times. Therefore, in practice, most of the evolution can be studied by using the linear theory, simplifying the problem considerably.

The nonlinear waves in a sheared liquid film on a horizontal plate at small Reynolds numbers are examined by theoretical and numerical approaches. The analysis employs the long-wave approximation along with finite difference schemes. The results show that the surface tension can suppress disturbances and prevent the occurrence of singularities. While the film flow is driven by the shear stress on the interface, its instability highly depends on the magnitude and direction of gravity. Specifically, when the direction of gravity is opposite to the wall-normal direction, perturbations are stabilized by gravity. In contrast, when these two directions are the same, the gravitational force is destabilizing, and stationary travelling waves can exist if a balance is reached between the effects of gravity and surface tension. For the steady solitary waves, there are quasi-periodic oscillations occurring between two stationary points, indicating the presence of heteroclinic trajectories. For periodic waves, the evolutions are sensitive to several parameters and initial disturbances, while one steady-state wave exhibits a sine function-like behaviour.

In confined systems, the entrapment of a gas volume with an equivalent spherical diameter greater than the dimension of the channel can form extended bubbles that obstruct fluid circuits and compromise performance. Notably, in sealed vertical tubes, buoyant long bubbles cannot rise if the inner tube radius is below a critical value near the capillary length. This critical threshold for steady ascent is determined by geometric constraints related to the matching of the upper cap shape with the lubricating film surrounding the elongated part of the bubble. Developing strategies to overcome this threshold and release stuck bubbles is essential for applications involving narrow liquid channels. Effective strategies involve modifying the matching conditions with an external force field to facilitate bubble ascent. However, it is unclear how changes in acceleration conditions affect the motion onset of buoyancy-driven long bubbles. This study investigates the mobility of elongated bubbles in sealed tubes with an inner radius near the critical value inhibiting bubble motion in a vertical setting. Two strategies are explored to tune bubble motion, leveraging variations in axial and transversal accelerations: tube rotation around its axis and tube inclination relative to gravity. By revising the geometrical constraints of the simple vertical setting, the study predicts new thresholds based on rotational speed and tilt angle, respectively, providing forecasts for the bubble rising velocity under modified apparent gravity. Experimental measurements of motion threshold and rising velocity compare well with theoretical developments, thus suggesting practical approaches to control and tune bubble motion in confined environments.

We study liquid plugs in the pulmonary airways based on the two-phase axisymmetric weighted residual integral boundary-layer model of Dietze et al. (J. Fluid Mech., vol. 894, 2020, A17), which was originally developed to study liquid films coating the inner surface of a cylindrical tube in interaction with a core gas flow. The augmented form of this model, which was never applied beyond a proof of concept, allows for the representation of liquid pseudo-plugs. Here, we demonstrate its predictive power vs experiments and direct numerical simulations, in terms of the dynamics of plug formation and the characteristics of developed liquid plugs, such as their shape, flow field, speed and length, as well as the associated wall stresses and their spatial derivatives. In particular, we show that the augmented model allows us to establish a direct continuation path from travelling-wave solutions (TWS) to travelling-plug solutions (TPS). We then apply the model to predict mucus plugs in the conducting zone of the tracheobronchial tree, based on the lung architecture model of Weibel. We proceed by numerical continuation of travelling-state solutions in terms of the airway generation, whereby we impose the wavelength of the linearly most-amplified convective instability (CI) mode or that of the absolute instability (AI) mode. We identify the critical airway generation for liquid-plug formation (TWS/TPS transition), maximum potential for wall-stress-induced epithelial cell damage and CI/AI transition, and investigate how these phenomena are affected by the main control parameters, i.e. airway orientation vs gravity, air flow rate, mucus properties and airway size.

We derive a generalised asymptotic model for the flow of a thin fluid film over an arbitrarily parameterised non-axisymmetric curved substrate surface based on the lubrication approximation. In addition to surface tension, gravity and centrifugal force, our model incorporates the effects of the Coriolis force and disjoining pressure, together with a non-uniform initial condition, which have not been widely considered in existing literature. We use this model to investigate the impact of the Coriolis force and fingering instability on the spreading of a non-axisymmetric spin-coated film at a range of substrate angular velocities, first on a flat substrate, and then on parabolic cylinder- and saddle-shaped curved substrates. We show that, on flat substrates, the Coriolis force has a negligible impact at low angular velocities, and at high angular velocities results in a small deflection of fingers formed at the contact line against the direction of substrate rotation. On curved substrates, we demonstrate that, as the angular velocity is increased, spin-coated films transition from being dominated by gravitational drainage with no fingering to spreading and fingering in the direction with the greatest component of centrifugal force tangent to the substrate surface. For both curved substrates and all angular velocities considered, we show that the film thickness and total wetted substrate area remain similar over time to those on a flat substrate, with the key difference being the shape of the spreading droplet.

When placed at the surface of a volatile liquid, a sphere of hot dense non-volatile material remains suspended until it cools sufficiently. The duration of this ‘inverse Leidenfrost’ phenomenon depends on the Nusselt number $Nu$ of the sphere, itself determined by flow in the film of vapour separating particle and liquid. It is shown that provided the Nusselt number is large, it can be calculated numerically using only the Laplace relation and the equations governing the thin film; patching to a solution for the outer thick film is not necessary. This method is demonstrated by using it to determine $Nu$ for a sphere sufficiently small that in the governing equations, the acceleration due to gravity is negligible except where multiplied by the density of the sphere. Numerical results giving $Nu$ as a function of a dimensionless measure of sphere weight are supplemented with analysis showing that, when the weight is of the order of the maximum supportable by surface tension alone, the film consists of a spherical bubble cap bounded by its contact rim. The solutions for these regions are coupled: although the apparent contact angle $\chi$ for the cap is determined within the rim, its value depends on the flow rate arriving from the cap as well as on the additional evaporation from the rim. The latter acts to reduce $\chi$ from the value it would otherwise have, thereby reducing the thickness of the entire cap. For the example treated here, the value of $Nu$ is doubled by this mechanism.

Free surface flows driven by boundary undulations are observed in many biological phenomena, including the feeding and locomotion of water snails. To simulate the feeding strategy of apple snails, we develop a centimetric robotic undulator that drives a thin viscous film of liquid with the wave speed $V_w$. Our experimental results demonstrate that the behaviour of the net fluid flux $Q$ strongly depends on the Reynolds number $Re$. Specifically, in the limit of vanishing $Re$, we observe that $Q$ varies non-monotonically with $V_w$, which has been successfully rationalised by Pandey et al. (Nat. Commun., vol. 14, no. 1, 2023, p. 7735) with the lubrication model. By contrast, in the regime of finite inertia (${Re} \sim O(1)$), the fluid flux continues to increase with $V_w$ and completely deviates from the prediction of lubrication theory. To explain the inertia-enhanced pumping rate, we build a thin-film, two-dimensional model via the asymptotic expansion in which we linearise the effects of inertia. Our model results match the experimental data with no fitting parameters and also show the connection to the corresponding free surface shapes $h_2$. Going beyond the experimental data, we derive analytical expressions of $Q$ and $h_2$, which allow us to decouple the effects of inertia, gravity, viscosity and surface tension on free surface pumping over a wide range of parameter space.

Liquid bridges are formed when a flowing liquid interacts with multiple parallel fibres, as relevant to heat and mass transfer applications that utilize flow down fibre arrays. We perform a comprehensive experimental study of flowing liquid bridges between two vertical fibres whose spacing is controlled dynamically in our experimental apparatus. The bridge patterns exhibit a regular periodic spacing typical of absolute instability for low flow rates, but become spatially inhomogeneous above a critical flow rate where the base flow is convectively unstable. The shapes of individual bridges and their associated dynamics are measured, as they depend upon the liquid properties, and fibre geometry/spacing. The bridge length scales similarly to static bridges between parallel fibres. The bridge dynamics exhibits a dependence on viscosity and scale with the impedance. A simple energy balance is used to derive a scaling relationship for the bridge velocity that captures the general trend of our experimental data. Finally, we demonstrate that these scalings similarly apply when the fibres are dynamically separated or brought together.

We study the influence of a low-frequency harmonic vibration on the formation of the two-dimensional rolling solitary waves in vertically co-flowing two-layer liquid films. The system consists of two adjacent layers of immiscible fluids with the first layer being sandwiched between a vertical solid plate and the second fluid layer. The solid plate oscillates harmonically in the horizontal direction inducing Faraday waves at the liquid–liquid and liquid–air interfaces. We use a reduced hydrodynamic model derived from the Navier–Stokes equations in the long-wave approximation. Linear stability of the base flow in a flat two-layer film is determined semi-analytically using Floquet theory. We consider sub-millimetre-thick films and focus on the competition between the long-wavelength gravity-driven and finite wavelength Faraday instabilities. In the linear regime, the range of unstable wave vectors associated with the gravity-driven instability broadens at low and shrinks at high vibration frequencies. In nonlinear regimes, we find multiple metastable states characterized by solitary-like travelling waves and short pulsating waves. In particular, we find the range of the vibration parameters at which the system is multistable. In this regime, depending on the initial conditions, the long-time dynamics is dominated either by the fully developed solitary-like waves or by the shorter pulsating Faraday waves.

A phenomenological model is proposed to estimate the initial thickness of the liquid microlayer forming beneath a vapour bubble growing on a solid surface upon nucleate boiling. The model employs an analogy between the microlayer formation and the classic plate withdrawal problem. It calculates the microlayer thickness by considering it as a Landau–Levich film, where the thickness is a function of the meniscus speed and radius of curvature. Given the nearly hemispherical shape of the bubble during the early growth stage when the microlayer is first deposited, we assume that the meniscus speed can be approximated by the bubble expansion rate, and estimate the meniscus curvature using the Rayleigh equations. Unlike previous theories that assume that the bubble radius growth is proportional to the square root of time, the proposed model does not rely on any specific law of growth for vapour bubbles. The model is validated for predicting the microlayer thickness in water and ethanol, showing good agreement with experimental measurements and empirical correlations. Subsequent analyses of the microlayer interface profile address inconsistent reports – some described a wedge-like shape, whereas others reported a slight outward curvature with decreasing thickness in the outer region. This discrepancy is attributed to a reduction in the expansion rate of the microlayer's outer edge, particularly when the bubble reaches its maximum width. Our model provides insights into microlayer dynamics, essential to boiling heat transfer, as the evaporative heat flux through the microlayer is very sensitive to its initial thickness.