A range of two- and three-dimensional problems is explored featuring the gravity-driven flow of a continuous thin liquid film over a non-porous inclined flat surface containing well-defined topography. These are analysed principally within the framework of the lubrication approximation, where accurate numerical solution of the governing nonlinear equations is achieved using an efficient multigrid solver. Results for flow over one-dimensional steep-sided topographies are shown to be in very good agreement with previously reported data. The accuracy of the lubrication approximation in the context of such topographies is assessed and quantified by comparison with finite element solutions of the full Navier–Stokes equations, and results support the consensus that lubrication theory provides an accurate description of these flows even when its inherent assumptions are not strictly satisfied. The Navier–Stokes solutions also illustrate the effect of inertia on the capillary ridge/trough and the two-dimensional flow structures caused by steep topography. Solutions obtained for flow over localized topography are shown to be in excellent agreement with the recent experimental results of Decré & Baret (2003) for the motion of thin water films over finite trenches. The spread of the ‘bow wave’, as measured by the positions of spanwise local extrema in free-surface height, is shown to be well-represented both upstream and downstream of the topography by an inverse hyperbolic cosine function. An explanation, in terms of local flow rate, is given for the presence of the ‘downstream surge’ following square trenches, and its evolution as trench aspect ratio is increased is discussed. Unlike the upstream capillary ridge, this feature cannot be completely suppressed by increasing the normal component of gravity. The linearity of free-surface response to topographies is explored by superposition of the free surfaces corresponding to two ‘equal-but-opposite’ topographies. Results confirm the findings of Decré & Baret (2003) that, under the conditions considered, the responses behave in a near-linear fashion.

Experiments reported by Blake et al. [Phys. Fluids., 11, 1995 (1999)] suggest that the dynamic contact angle formed between the free surface of a liquid and a moving solid boundary at a fixed contact-line speed depends on the flow field and geometry near the moving contact line. We examine quantitatively whether or not it is possible to attribute this effect to the bending of the free surface due to hydrodynamic stresses acting upon it and hence interpret the results in terms of the so-called “apparent” contact angle. It is shown that this is not the case. Numerical analysis of the problem demonstrates that, at the spatial resolution reported in the experiments, the variations of the “apparent” contact angle (defined in two different ways) caused by variations in the flow field, at a fixed contact-line speed, are too small to account for the observed effect. The results clearly indicate that the actual (macroscopic) dynamic contact angle—i.e., the one used in fluid mechanics as a boundary condition for the equation determining the free surface shape—must be regarded as dependent not only on the contact-line speed but also on the flow field and geometry in the vicinity of the moving contact line.

The coalescence and mixing of a sessile and an impacting liquid droplet on a solid surface are studied experimentally and numerically in terms of lateral separation and droplet speed. Two droplet generators are used to produce differently colored droplets. Two high-speed imaging systems are used to investigate the impact and coalescence of the droplets in color from a side view with a simultaneous gray-scale view from below. Millimeter-sized droplets were used with dynamical conditions, based on the Reynolds and Weber numbers, relevant to microfluidics and commercial inkjet printing. Experimental measurements of advancing and receding static contact angles are used to calibrate a contact angle hysteresis model within a lattice Boltzmann framework, which is shown to capture the observed dynamics qualitatively and the final droplet configuration quantitatively. Our results show that no detectable mixing occurs during impact and coalescence of similar-sized droplets, but when the sessile droplet is sufficiently larger than the impacting droplet vortex ring generation can be observed. Finally we show how a gradient of wettability on the substrate can potentially enhance mixing.