The deposition and coating of thin films onto curved rigid substrate, involving displacement of air by a liquid, has numerous applications within the technology sectors but faces two major challenges: (i) control of the local film thickness; (ii) ensuring that the coating remains stable. The work reported here investigates the full coverage of three-dimensional curved geometries, of hemispherical and conical shape, by a continuously fed, gravity-driven, thin liquid layer. The modelling approach adopted utilises a first integral formulation [1, 2] of the Navier-Stokes equations leading to a variational formulation in the case of steady flow and an advantageous re-formulation of the dynamic boundary condition at the free surface [3]. Asymptotic analysis, underpinned by the long-wave approximation, enables analytic solutions for the local film thickness to be obtained.
Formulation
Problem definitionConsider the case of a continuous, steady, gravity-driven, incompressible film flow over a hemispherical or conical surface, as illustrated in Fig. 1, formed via a Newtonian liquid fed from above, with particular interest directed at the resulting free surface profile. (a) z r r 0 ϑV (b) z r y x α V Fig. 1 Gravity driven film flow over: (a) a hemisphere of radius r0; (b) a cone with inclination angle α.Both are continuously fed, with volumetric flow rateV , from above. Spherical (r, ϑ) and cylindrical (r, z) coordinate systems are employed for the hemisphere and cone, respectively; the equations of motion, once formulated, are transformed to natural coordinates as follows x = −z sin α+r cos α, y = z cos α + r cos α.
First Integral variational approach for steady 3D flowIn [3] a first integral of the Navier-Stokes equation is derived in an analogous fashion to Maxwell's use of potential fields when developing his classical electro-magnetic theory. For steady flow, a traceless symmetric tensor potentialā ij and a scalar potential Φ are introduced as auxiliary unknowns allowing derivation of the equations of motion from the variational principle:in terms ofā ij , Φ and the streamfunction vector Ψ k ; the velocity components given via u i = ε ijk ∂ j Ψ k , with ε ijk Levi-Civita symbol, fulfil the continuity equation ∂ i u i = 0 automatically. Taking the divergence of the tensor equation resulting via variation with respect toā ij , recovers the Navier-Stokes equations exactly [3]. Likewise, the dynamic boundary condition related to stress equilibrium at a free surface can be recasted in the form of a first integral of the tensor potential:where σ s is the surface tension and U the potential energy density of an external conservative force. The mathematical formulation is completed by the kinematic boundary condition at a free surfaces and the no-slip/no-penetration condition at a solid boundary.
Implementation for axisymmetric flowsIn terms of both coordinate systems, q 1 = r, q 2 = ϑ, q 3 = ϕ for the hemisphere and q 1 = z, q 2 = r, q 3 = ϑ, for the cone, the flow is clearly independent of the azimuthal angle ϕ, allowing fo...