behaviour of the characteristic meniscus curvature
scaled to the reciprocal film thickness, with a growth
followed by a drop as a function of Ca, is predicted,
in qualitative accordance with earlier experimental
observations and computational results.
2 Accomplishments and Challenges in
the Film Coatings
Derjaguin [4] proposed a "load" h, i.e. the thickness
of the film for the liquid adhering to the plate
h=(μu0/ρgsinα)1/2 (h=d0(sinα)1/2), assuming that the
effects of inertia and surface tension are weak. In [2],
an infinite plate (at an angle α to the horizontal at a
constant velocity u0) is considered from an infinite
pool of a viscous liquid, where the above formula
obtained from the Stokes equations within the
boundaries of small slopes of the plate (without this
assumption, the formula is invalid).
The problem was shown to have infinitely many
stable solutions; all of them are stable but only one
corresponds to the above formula. This stable
solution can be distinguished only by comparing it
with a self-similar solution describing the non-steady
part of the film flow between the pool and the tip of
the film. Although the area of the near-pool region in
which the stable state is established expands with
time, the upper non-steady part of the film (its
thickness decreases to the tip) expands faster as it was
shown. It occupies most of the plate; therefore, an
average thickness of the film is 1.5 times smaller than
the load.
For the case of thick films, the formula [4] has
been given without strict derivation, showing that in
this case the thickness of the layer is independent of
a surface tension of a liquid. In [2]it was derived more
in detail considered the profile of a liquid layer which
remains on the wall of a vessel, inclined at an angle
to the horizon, at a time t after the level of the liquid
has begun to recede. It was supposed that the
condition dh/dx<<1 for a thickness h of a film at the
given point, is satisfied everywhere, except at the
place, where the film goes over into the free volume
of a liquid. Publication [4] was delayed due to the
discovery of divergences from experiment, the
explanation for which was found later. The
experimental data [2] fully confirm the theory
including the numerical coefficients.
The work of Landau and Levich [3] (1942)
initiated the fundamental theoretical, as well as
experimental investigation of a flow of the thin liquid
film entrained by a steady withdrawal of a flat plate
from a liquid bath. The existing theories are based on
a linearization of the problem and differ substantially.
They give relationships between the film
thickness h and the capillary number Ca. For
example, the paper [5] demonstrated theoretically
that different physical properties for the different
liquids result not in a single function but in a family
of the functions h(Ca). The complete set of previous
experimental work fitted the family of curves, while
the previous theories could satisfy just some of this
experimental data. The solution was found applying
the nonlinear theory [5]. The inertial terms and two‐
dimensional flow together with the parameter of
liquid physical properties were accounted. The direct
method of Galerkin was applied for solution of the
nonlinear problem; therefore, the new theory has got
an advantage of accurately determining the shape and
size of the upper meniscus profile. With the complete
set of the available experimental data achieved an
excellent agreement with the theoretical results. The
classical formula [4] was derived more in detail in
[6]. For the case of thick films, it has been given
without strict derivation, showing, in particular, that
in this case the thickness of a layer does not depend
on the surface tension of a liquid.
The classical coating problem of determining
the asymptotic film thickness on a flat plate, which is
being withdrawn vertically from an infinitely deep
liquid pool, has been examined through a numerical
solution of the stationary Navier-Stokes equations
[7]. For the creeping flow, the dimensionless load q
was determined as a function of the capillary
number Ca. For Ca<0.4, an agreement of the
Wilson’s extension [8] with the Levich’s well-known
expression was found. But for Ca→∞, q asymptotes
to 0.582, below the value of 2∕3 by Deryagin and Levi
[9]. For the finite Reynolds numbers Re≡mCa3∕2,
where m is a dimensionless number involving only
the gravitational acceleration g and the properties of
the fluid, q was found independent of the m at a
given Ca. Nevertheless, it was revealed correct only
up to a critical capillary number Ca*, dependent
on m, beyond which their numerical scheme failed.
Similarly, the corresponding nondimensional
flow rate qα≡q(cosα)1∕2 depends on both Ca and α
for the creeping flows in case of the inclined plate (at
an angle α to a vertical). Its maximum has been found
to increase monotonically with α up to 2∕3 when
α exceeds a critical angle αc∼π∕4, where the plate was
inclined midway to the horizontal with its
coating surface on the topside.
Nonlinear free coating onto a vertical surface was
studied theoretically in [10]. When a vessel of liquid
has been emptied and put aside, a thin film of liquid
clings to the inside and gradually drains down to the
bottom under the action of gravity [11]. The layer
being thin, the motion is very nearly laminar flow,
WSEAS TRANSACTIONS on FLUID MECHANICS
DOI: 10.37394/232013.2022.17.11