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Capillary currents and viscous droplet spreading

Published online by Cambridge University Press:  09 June 2026

David Darrow*
Affiliation:
Department of Mathematics, Massachusetts Institute of Technology, Cambridge, MA 02139, USA
Lucas Warwaruk
Affiliation:
Department of Mechanical Engineering, Massachusetts Institute of Technology, Cambridge, MA 02139, USA
John W.M. Bush*
Affiliation:
Department of Mathematics, Massachusetts Institute of Technology, Cambridge, MA 02139, USA
*
Corresponding authors: David Darrow, ddarrow@mit.edu; John W.M. Bush, bush@math.mit.edu
Corresponding authors: David Darrow, ddarrow@mit.edu; John W.M. Bush, bush@math.mit.edu

Abstract

We present the results of a combined experimental and theoretical study of the spreading of viscous droplets over rigid substrates. First, we experimentally investigate the wetting of a roughened glass surface by a viscous droplet of silicone oil, wide and shallow relative to the capillary length $\ell _c$. The horizontal radius of the droplet grows according to an $R_{\textit{drop}}\sim t^{1/8}$ scaling, reminiscent of viscous gravity currents (Lopez et al. 1976 J. Colloid Interface Sci., vol. 56, pp. 460–468). The droplet is preceded by a mesoscopic fluid film that percolates through the rough substrate, its radius increasing according to $R_{\textit{film}}\sim t^{3/8}/(\log t)^{1/2}$. To rationalise these observed scalings, we develop a new ‘capillary current’ model for the spreading of shallow droplets with arbitrary radius on rough surfaces. Furthermore, on the basis of established similarities between droplet spreading over wetted rough and smooth substrates (Cazabat & Cohen Stuart, 1986 J. Phys. Chem., vol. 90, pp. 5845–5845), we argue its relevance to a broader class of spreading problems. We propose that, throughout their evolution, shallow droplets maintain a quasi-equilibrium balance between hydrostatic and curvature pressure, perturbed only by unbalanced contact line forces arising along the droplet’s edge. For drops with horizontal radii small with respect to $\ell _c$, our model converges to the original description of Hervet & de Gennes (1984 C. R. Acad. Sci. II, vol. 299, pp. 499–503) and thereby recovers the classic spreading laws of Hoffman (1975 J. Colloid Interface Sci., vol. 50, pp. 228–241), Voinov (1976 Fluid Dyn., vol. 11, pp. 714–721) and Tanner (1979 J. Phys. D: Appl. Phys. vol. 12, p. 1473). For drops wide with respect to $\ell _c$, it rationalises why millimetric, surface-tension-driven capillary currents exhibit the same spreading behaviour as relatively large-scale viscous gravity currents.

Information

Type
JFM Papers
Copyright
© The Author(s), 2026. Published by Cambridge University Press
Figure 0

Figure 1. Schematic of the physical system under investigation. (a) The droplet forms the rounded shape (2.7) of radius $R_1$, contact angle $\theta$ and maximum depth $h_1=h(0)\ll \ell _c$. In the case of total wetting, the droplet is generally preceded by a precursor film of thickness $h_2\ll h_1$ and radius $R_2\geqslant R_1$. (b) A small droplet ($R_1\ll \ell _c$) approximately forms a spherical cap with a maximum depth $h_1 \sim R_1\theta /2$. (c) A large droplet ($R_1\gg \ell _c$) is shaped more like a flat disk, with a depth $h_1 \sim \ell _c \tan \theta$ that is approximately constant for $r \lt R_1 - \ell _c$. (d) If the substrate is smooth, a microscopic precursor film arises with thickness $h_2$ on the molecular scale. (e) If the substrate is rough, a Darcy precursor film arises with thickness comparable to the roughness height (in the case of our experiments, approximately 10 ${\unicode{x03BC}}\textrm{m}$). The zoom box in (d) illustrates the net horizontal surface tension force $f=\sigma (1-\cos \theta )\sim \sigma \theta ^2/2$ acting radially outward on the apparent contact line; such a force is present on both smooth and rough substrates. In all cases, the radius $R_1$ grows with time, while $\theta$ and $h_1$ decrease.

Figure 1

Figure 2. (a) Confocal microscope scan of the surface S60, a borosilicate glass square sanded with 60 grit silicone-carbide lapping compound. (b) Annotated image of a silicone oil droplet wetting the surface S100, sanded instead with 100 grit compound. Shown below are several snapshots of the spreading process, with the drop diameter $2R_1$ (blue arrows) and precursor film diameter $2R_2$ (red arrows) indicated. (c–e) Time evolution of the drop radius $R_1$, the film radius $R_2$, and their difference $\Delta R = R_2-R_1$, for a $5$${\unicode{x03BC}}\textrm{l}$ silicone oil droplet ($\nu = 5$ cSt, $\sigma = 20$ mN m$^{-1}$, $\rho = 0.913$ g cm$^{-3}$) wetting both S60 and S100. The solid blue line in (c) represents the roughness-independent scaling $R_1 \sim t^{1/8}$ predicted for large droplets ($R_1\gg \ell _c$), and the dashed green line represents the scaling $R_1\sim t^{1/10}$ predicted for small droplets ($R_1\ll \ell _c$). These observations are consistent with our experiments being in the large-droplet regime. The solid red lines in (d) are fits of $R_2$ measurements, equal to $R_2(t) = At^{3/8}/[\log (Bt+C)]^{1/2}$ for surface-dependent parameters $A,B,C$. For the surface S100, the fitting coefficients are $A = 2.99$ mm s$^{-3/8}$, $B = 0.63$ s$^{-1}$ and $C = 2.62$. For the surface S60, the fitting coefficients are $A = 3.80$ mm s$^{-3/8}$, $B = 1.33$ s$^{-1}$ and $C = 3.79$. We rationalise the values of these parameters in Appendix A. We observe that neither curve adheres to the $t^{3/8}$ power law recovered from neglecting log factors in this fit. Finally, the dashed line in (d) represents the scaling $\Delta R(t) \sim t^{1/2}$ predicted by Washburn’s law of wicking, which is inconsistent with our observations. We note that previous experiments of viscous droplet spreading also report strong deviations from Washburn’s law (Cazabat & Cohen Stuart 1986; Dorbolo 2021). We rationalise these deviations in § 5.

Figure 2

Table 1. Material properties of the different test fluids in § 3.3.

Figure 3

Figure 3. Evolution of (a) the droplet radius $R_1(t)$ and (b) the Darcy precursor film radius $R_2(t)$ for silicone oils of kinematic viscosity $\nu = 5$, $10$ and $50$ cSt on the surface S100. When non-dimensionalised with respect to the capillary length $\ell _c$ and plotted against the dimensionless time $\hat {t} = t\ell _c/u_c$, all three measurements of $R_1$ align closely with a single $R_1(\hat {t})/\ell _c \sim \hat {t}^{1/8}$ curve (blue), and all three measurements of $R_2$ align closely with a single $R_2( \hat {t}) = A \hat {t}^{3/8}/[\log (B \hat {t}+C)]^{1/2}$ curve (red), where $A = 0.10$, $B = 2.0 \times 10^{-4}$ and $C = 2.50$.

Figure 4

Table 2. Scalings predicted by our model in various limits of interest, for both one-dimensional and axisymmetric two-dimensional systems. Here, $R_1$, $h_1$ and $\theta$ are the horizontal radius, depth and apparent contact angle of the droplet bulk, $R_2$ is the radius of the Darcy precursor film on a rough substrate and $\Delta R=R_2-R_1$. The scalings reported for $\dot {R}_1$, $R_1$, $h_1$ and $\theta$ are predicted to hold for droplets totally wetting either smooth or rough substrates, but we clarify that we do not predict the spreading rate of a microscopic precursor film on a smooth substrate. The $\dot {R}_1\sim \theta ^3$ scaling of Hoffman (1975) and Hervet & de Gennes (1984) arises in the small-droplet limit in both one- and two-dimensional systems. The $R_1\sim V^{3/10}t^{1/10}$ and $\theta \sim V^{1/10}t^{-3/10}$ laws of Voinov (1976) and Tanner (1979) arise in the small-droplet limit in two dimensions. The $R_1\sim V^{3/7}t^{1/7}$ scaling of Tanner (1979) and McHale et al. (1995) arises in the small-droplet limit in one dimension. The $\Delta R\sim t^{1/2}$ law of Washburn (1921) arises in the limit of a tension-driven film dynamics. The $R_1\sim V^{3/8}t^{1/8}$ scaling observed by Lopez et al. (1976) arises for large droplets in two dimensions.

Figure 5

Figure 4. (a) Downsampled version of the data recorded by Dorbolo (2021) for the spreading of a Darcy precursor film ahead of a small drop of 20 cSt silicone oil on a frosted glass substrate. The radius $R_2$ of the film undergoes three distinct spreading regimes: $R_2\sim t^{3/10}$ for the intermediate time regime ($t\lesssim 10^5$ s) of present interest, $R_2\sim t^{3/20}$ after the droplet bulk sinks into the surface roughness ($10^5$ s $\lesssim t\lesssim 10^7$ s); and $R_2\sim \textrm{const}.$ at very late times ($t\gtrsim 10^7$ s). Although Dorbolo originally inferred that the first spreading regime was driven by wicking, with deviations from Washburn’s law (§ 2.5) caused by irregular roughness elements, we note that the observed scaling $R_2\sim t^{3/10}$ is consistent with our predictions for overpressure-driven Darcy precursor films ahead of small drops. (b) The data recorded by de Ruijter et al. (1999) for the spreading of a partially wetting, viscous drop of DBP on a smooth PET substrate, along with two fitted curves reproduced from Durian et al. (2022): the predicted behaviour of the droplet if the equilibrium radius were $R_{\textit{eq}}=0.5$ cm (green); and the predicted early-time spreading behaviour, independent of $R_{\textit{eq}}$ (blue). A natural extension of our work to partially wetting drops yields the evolution equation (5.1), which reproduces the predictions of Durian et al. (2022) for both large and small drops with a purely edge-driven model. (c) Data reported by Cazabat & Cohen Stuart (1986) for the spreading of viscous drops of methyl-terminated poly dimethylsiloxane (PMS) on smooth glass, depicting the small-to-large-droplet transition as $R_1$ exceeds the capillary length. Also shown are the asymptotic $R_1\sim t^{1/10}$ and $R_1\sim t^{1/8}$ curves (dashed red) for both $V=1.5$ and $V=0.8$${\unicode{x03BC}}\textrm{l}$, reproduced from Cazabat & Cohen Stuart (1986), and the predictions of our own model for both cases (blue). Specifically, we report the predictions of the evolution equation (4.8) augmented with the three dissipation terms present in (4.6), with the fitted coefficients $\alpha =1$, $\beta =15$, $\kappa = 150$.