Abstract
As in many areas of science and technology, computational mathematics performed on highspeed, large-memory computers has become an essential ingredient of modern coating process research and development. Traditionally, most advances in the manufacture of imaging films, magnetic storage and many other precision coatings have been based on extensive experimentation. A predominantly empirical approach was sufficient to achieve a remarkable level of technological perfection. Nowadays, however, rapidly intensifying competitive pressures demand ever increasing coating speeds, thinner and more uniform coatings (often multilayered), reduced defect levels and diminished waste. Further refinements in coating technology become increasingly intricate and put a premium on analyzing the physical mechanisms that determine success or failure of a coating process. Imperfections in a coated layer may arise from a wide variety of mechanisms, including inhomogeneities or foreign matter in the coating solutions, disturbances induced by equipment vibration or uncontrolled air flow, various wetting phenomena, and also flow instabilities that grow in the coating device but partially decay further downstream. Complete coating failure, on the other hand, almost exclusively arises fromcatastrophic hydrodynamic instabilities. It is often aggravated by edge effects, and might be triggered by large transients of the sort encountered during start-up or splice passage. Catastrophic coating failure may also stem from the inability of the coating liquid to displace sufficient air previously in contact with the dry substrate.
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Christodoulou, K.N., Kistler, S.F., Schunk, P.R. (1997). Advances in Computational Methods for Free-Surface Flows. In: Kistler, S.F., Schweizer, P.M. (eds) Liquid Film Coating. Springer, Dordrecht. https://doi.org/10.1007/978-94-011-5342-3_9
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