Thinning and rupture of a thin film of a power-law fluid on a solid substrate under the balance between destabilizing van der Waals pressure and stabilizing capillary pressure is analysed. In a power-law fluid, viscosity is not constant but is proportional to the deformation rate raised to the $n-1$ power, where $0<n\leqslant 1$ is the power-law exponent ($n=1$ for a Newtonian fluid). In the first part of the paper, use is made of the slenderness of the film and the lubrication approximation is applied to the equations of motion to derive a spatially one-dimensional nonlinear evolution equation for film thickness. The variation with time remaining until rupture of the film thickness, the lateral length scale, fluid velocity and viscosity is determined analytically and confirmed by numerical simulations for both line rupture and point rupture. The self-similarity of the numerically computed film profiles in the vicinity of the location where the film thickness is a minimum is demonstrated by rescaling of the transient profiles with the scales deduced from theory. It is then shown that, in contrast to films of Newtonian fluids undergoing rupture for which inertia is always negligible, inertia can become important during thinning of films of power-law fluids in certain situations. The critical conditions for which inertia becomes important and the lubrication approximation is no longer valid are determined analytically. In the second part of the paper, thinning and rupture of thin films of power-law fluids in situations when inertia is important are simulated by solving numerically the spatially two-dimensional, transient Cauchy momentum and continuity equations. It is shown that as such films continue to thin, a change of scaling occurs from a regime in which van der Waals, capillary and viscous forces are important to one where the dominant balance of forces is between van der Waals, capillary and inertial forces while viscous force is negligible.

Abstract

The fluid dynamics of the collision and coalescence of liquid drops has intrigued scientists and engineers for more than a century owing to its ubiquitousness in nature, e.g. raindrop coalescence, and industrial applications, e.g. breaking of emulsions in the oil and gas industry. The complexity of the underlying dynamics, which includes occurrence of hydrodynamic singularities, has required study of the problem at different scales – macroscopic, mesoscopic and molecular – using stochastic and deterministic methods. In this work, a multi-scale, deterministic method is adopted to simulate the approach, collision, and eventual coalescence of two drops where the drops as well as the ambient fluid are incompressible, Newtonian fluids. The free boundary problem governing the dynamics consists of the Navier–Stokes system and associated initial and boundary conditions that have been augmented to account for the effects of disjoining pressure as the separation between the drops becomes of the order of a few hundred nanometres. This free boundary problem is solved by a Galerkin finite element-based algorithm. The interplay of inertial, viscous, capillary and van der Waals forces on the coalescence dynamics is investigated. It is shown that, in certain situations, because of inertia two drops that are driven together can first bounce before ultimately coalescing. This bounce delays coalescence and can result in the computed value of the film drainage time departing significantly from that predicted from existing scaling theories.

A common feature of many free surface flows—drop/bubble breakup or coalescence and film/sheet rupture—is the occurrence of hydrodynamic singularities. Accurately computing such flows with continuum mechanical, multidimensional free surface flow algorithms is a challenging task given these problems’ multiscale nature, which necessitates capturing dynamics occurring over disparate length scales across 5–6 orders of magnitude. In drop breakup, the thinning of fluid threads that form and eventually pinch-off must be simulated until the thread's radius is about 10 nm. When two drops approach one another, the thickness of the fluid film separating them must fall below 10 nm before coalescence is said to have occurred. If the initial drop radii are 1 mm, simulations must remain faithful to the physics as thread radius or film thickness falls from 10−3 m to below 10−8 m. Here we review significant findings in interfacial flows with hydrodynamic singularities spearheaded by sharp interface algorithms. These multidimensional algorithms can achieve resolution that to date has only been possible with the use of simple 1D evolution equations. Expected final online publication date for the Annual Review of Fluid Mechanics, Volume 55 is January 2023. Please see http://www.annualreviews.org/page/journal/pubdates for revised estimates.

Abstract