Numerical bifurcation analysis of a film flowing over a patterned surface through enhanced lubrication theory

The bifurcation analysis of a film falling down an hybrid surface is conducted via the numerical solution of the governing lubrication equation. Instability phenomena, that lead to film breakage and growth of fingers, are induced by multiple contamination spots. Contact angles up to 75◦ are investigated due to the full implementation of the free surface curvature, which replaces the small slope approximation, accurate for film slope lower than 30◦ . The dynamic contact angle is first verified with the Hoffman–Voinov–Tanner law in case of a stable film down an inclined plate with uniform surface wettability. Then, contamination spots, characterized by an increased value of the static contact angle, are considered in order to induce film instability and several parametric computations are run, with different film patterns observed. The effects of the flow characteristics and of the hybrid pattern geometry are investigated and the corresponding bifurcation diagram with the number of observed rivulets is built. The long term evolution of induced film instabilities shows a complex behavior: different flow regimes can be observed at the same flow characteristics under slightly different hybrid configurations. This suggest the possibility of controlling the rivulet/film transition via a proper design of the surfaces, thus opening the way for relevant practical application.