A unified theory of instabilities in viscoelastic thin films: from wetting to confined films, from viscous to elastic films, and from short to long waves

Optical Tweezers-Based Measurements of Colloidal Forces between Asphaltene Thin Films: Effect of Ultrasonication

Oil production and processing often involve the treatment of water-in-oil emulsions stabilized by asphaltenes. The asphaltenes adsorb irreversibly at the water-oil interface and, by self-association at the interface, form a viscoelastic film that stabilizes the emulsions mechanically and sterically. Hydrophobic forces associated with these films may also contribute to the emulsion stability. A key step in treating these emulsions is to weaken the asphaltene film at the interface, and one way to do so is with ultrasonic treatment. The effect of ultrasonic waves on the interactions between asphaltene films was investigated at a silica-water interface using optical tweezers. Silica microparticles were aged in asphaltene solutions to form asphaltene coatings on their surfaces. The particles were dispersed in water, and interparticle force measurements were performed with optical tweezers to capture the steric force and hydrophobic force contributions. The asphaltene coating thickness and hydrophobic coefficient (a factor resembling the strength of the hydrophobic interaction) were obtained from fitting these forces. The effect of ultrasonication on the thickness of the asphaltene films on the surfaces of the particles was investigated. No change in the hydrophobic coefficient was observed upon changing the interfacial asphaltene concentration. The asphaltene film thickness increased with the concentration of the asphaltene solution and aging time. After treatment of the dispersion with ultrasonic waves for different durations (between 5 and 40 min), a significant reduction in the coating thickness was observed. This reduction was confirmed by thermogravimetric analysis (TGA) measurements. It is hypothesized that cavitation at the interface removed part of the surface layer of asphaltenes from the coated particles. Based on these findings, we proved that a low-power ultrasound field can effectively break asphaltene-stabilized water-in-oil emulsions.

Instability and rupture of ultrathin freestanding viscoelastic solid films

We analyze the instability of viscoelastic solid freestanding thin films under the influence of van der Waals forces using linear stability analysis and nonlinear simulations. Linear stability analysis shows that the zero-frequency elastic modulus governs the onset of instability and stabilizes the film beyond a critical value analogous to thin supported viscoelastic solid films. However, for freestanding solid films, the critical shear modulus is found to be independent of surface tension, unlike that of thin supported viscoelastic solid films. It is further shown that freestanding viscoelastic solid films with higher moduli can be destabilized for a given film thickness and Hamaker constant compared to supported solid films. In contrast to thin viscoelastic liquid films where the growth rate is enhanced due to elastic effects but length scale is unaltered, freestanding films with solidlike viscoelasticity show a retarded growth rate and enhanced length scale. The presence of solidlike viscoelasticity has a stabilizing effect and affects all the key aspects of instability such as critical wave number, dominant wave number, and maximum growth rate. We numerically solve the set of coupled nonlinear evolution equations for film thickness and tangential displacement in order to elucidate the dynamics of film rupture. Our simulations show that, consistent with the linear stability predictions, an increase in the elastic modulus delays film rupture. The dynamics exhibits self-similarity in the vicinity of film rupture and the film thins as (t_{r}-t)^{3/4}, where t_{r} is the rupture time and t_{r}-t is the time remaining until film rupture. The scaling exponent 3/4 obtained for a thin freestanding viscoelastic solid film is significantly greater than the scaling exponent (1/3) for a thin freestanding viscous film.

Critical Solutal Marangoni Number Correlation for Short-Scale Convective Instabilities in Drying Poly(vinyl acetate)-Methanol Thin Films

A new empiric correlation for the critical solutal Marangoni number as function of the Péclet and Schmidt numbers is proposed. It is based on previously published experimental flow field data in drying poly(vinyl acetate)-methanol films with an initial thickness in the range of 20–100 μm and an initial solvent load of 1 to 2 gMeOH/gPVAc, as well as newly derived concentration profile measurements and 1D drying simulations. The analysis accounts for realistic transient material properties and describes the occurrence of short-scale convective Marangoni (in)stabilities during the entire drying process with an accuracy of 9%. In addition, the proposed correlation qualitatively follows trends known from theory. As convective Marangoni instabilities in drying polymer films may induce surface deformations, which persist in the dry film, the correlation may facilitate future process design for either thin films with uniform thickness or deliberate self-assembly.

Transient Three-Dimensional Flow Field Measurements by Means of 3D µPTV in Drying Poly(Vinyl Acetate)-Methanol Thin Films Subject to Short-Scale Marangoni Instabilities

Convective Marangoni instabilities in drying polymer films may induce surface deformations, which persist in the dry film, deteriorating product performance. While theoretic stability analyses are abundantly available, experimental data are scarce. We report transient three-dimensional flow field measurements in thin poly(vinyl acetate)-methanol films, drying under ambient conditions with several films exhibiting short-scale Marangoni convection cells. An initial assessment of the upper limit of thermal and solutal Marangoni numbers reveals that the solutal effect is likely to be the dominant cause for the observed instabilities.

Infrared microlenses and gratings of chalcogenide: confined self-organization in solution processed thin liquid films

This work demonstrates the fabrication of chalcogenide microstructures such as gratings, lenses and needles using a lithographically directed, evaporative self-organization of chalcogenide thin liquid films for the first time. Using a two-step annealing protocol, excess solvent of freshly coated ChG films is eliminated and then the liquid films are patterned using elastomeric masters with continuous or disconnected features during solvent evaporation. Although microcontact printing or capillary flow lithography has been proven to be useful to create continuous gratings and waveguide like structures in solid films, our method overcomes the limitation of structural continuity of the generated pattern and uses self-organization of solute ChG within the master's confinement to produce isolated microstructures. Fabrication of disjointed arrays of microlenses of various dimensions as well as conical shaped needles in ChG thin films has been demonstrated for relevant optical IR applications. This methodology establishes evaporative self-organization of ChG thin films as a viable alternative to creating microstructures in bulk ChG with hot-embossing, bypassing the need for ultra high temperature processing.

Directed self-organization of a glassy material is demonstrated to generate ultra smooth, optically useful micro structures such as lens arrays and gratings. Liquid thin films of chalcogenide re-organize within the confinement provided by the mould.

Instability, self-organization and pattern formation in thin soft films

The free surface of a thin soft polymer film is often found to become unstable and self-organizes into various meso-scale structures. In this article we classify the instability of a thin polymer film into three broad categories, which are: category 1: instability of an ultra-thin (<100 nm) viscous film engendered by amplification of thermally excited surface capillary waves due to interfacial dispersive van der Waals forces; category 2: instability arising from the attractive inter-surface interactions between the free surface of a soft film exhibiting room temperature elasticity and another rigid surface in its contact proximity; and category 3: instability caused by an externally applied field such as an electric field or a thermal gradient, observed in both viscous and elastic films. We review the salient features of each instability class and highlight how characteristic length scales, feature morphologies, evolution pathways, etc. depend on initial properties such as film thickness, visco-elasticity (rheology), residual stress, and film preparation conditions. We emphasize various possible strategies for aligning and ordering of the otherwise isotropic structures by combining the essential concepts of bottom-up and top-down approaches. A perspective, including a possible future direction of research, novelty and limitations of the methods, particularly in comparison to the existing patterning techniques, is also presented for each setting.

Hierarchical Micro/Nano Structures by Combined Self-Organized Dewetting and Photopatterning of Photoresist Thin Films

Photoresists are the materials of choice for micro/nanopatterning and device fabrication but are rarely used as a self-assembly material. We report for the first time a novel interplay of self-assembly and photolithography for fabrication of hierarchical and ordered micro/nano structures. We create self-organized structures by the intensified dewetting of unstable thin (∼10 nm to 1 μm) photoresist films by annealing them in an optimal solvent and nonsolvent liquid mixture that allows spontaneous dewetting to form micro/nano smooth dome-like structures. The density, size (∼100 nm to millimeters), and curvature/contact angle of the dome/droplet structures are controlled by the film thickness, composition of the dewetting liquid, and time of annealing. Ordered dewetted structures are obtained simply by creating spatial variation of viscosity by ultraviolet exposure or by photopatterning before dewetting. Further, the structures thus fabricated are readily photopatterned again on the finer length scales after dewetting. We illustrate the approach by fabricating several three-dimensional structures of varying complexity with secondary and tertiary features.

Adhesion-induced instabilities and pattern formation in thin films of elastomers and gels

A hydrostatically stressed soft elastic film circumvents the imposed constraint by undergoing a morphological instability, the wavelength of which is dictated by the minimization of the surface and the elastic strain energies of the film. While for a single film, the wavelength is entirely dependent on its thickness, a co-operative energy minimization dictates that the wavelength depends on both the elastic moduli and thicknesses of two contacting films. The wavelength can also depend on the material properties of a film if its surface tension has a pronounced effect in comparison to its elasticity. When such a confined film is subjected to a continually increasing normal displacement, the morphological patterns evolve into cracks, which, in turn, govern the adhesive fracture behavior of the interface. While, in general, the thickness provides the relevant length scale underlying the well-known Griffith-Kendall criterion of debonding of a rigid disc from a confined film, it is modified non-trivially by the elasto-capillary number for an ultra-soft film. Depending upon the degree of confinement and the spatial distribution of external stress, various analogs of the canonical instability patterns in liquid systems can also be reproduced with thin confined elastic films.

Miniaturized pattern formation in elastic films cast on sinusoidally patterned substrates

The various morphologies that are formed when van der Waals forces or electric field is induced between film cast on a sinusoidal substrate and in contact proximity with a contactor or electrode are studied. Remarkably smaller length scales are achieved (λc < 2.96h) than those obtained with films cast on flat substrates. With van der Waals interactions, the patterns are uniformly formed throughout the film but are not regularly ordered. When electric field is used at critical voltage, more ordered, localized patterns are formed at the zones of large local interaction strengths. When these patterns are evolved by increasing the applied voltage, coexistence of all three phases-cavities, stripes, and columns-is observed throughout the film. The localized patterns that are initially formed vary with the voltage applied and strongly dictate the phases of evolution. A patterned substrate/patterned contactor assembly can be made to operate like its unpatterned counterpart by making the interaction strength same everywhere and yet yield uniform, regularly ordered, highly miniaturized patterns. Such patterns are very useful in various applications like microfluidics; they are formed with great ease and can be morphologically tuned by tuning the externally applied electric field.

Mechanically modulated dewetting by atomic force microscope for micro- and nano- droplet array fabrication

Organizing a material into well-defined patterns during the dewetting process provides an attractive micro-/nano-fabrication method without using a conventional lithographic process, and hence, offers potential applications in organic electronics, optics systems, and memory devices. We report here how the mechanical modification of polymer surface by an Atomic Force Microscope (AFM) can be used to guide thin film dewetting evolution and break the intrinsic spatial correlation of spontaneous instability. An AFM is used to implement the mechanical modification of progressively narrow grids to investigate the influence of pattern size on the modulation of ultrathin polystyrene films dewetting evolution. For films with different initial thicknesses, when grid size is close to or below the characteristic wavelength of instability, the spinodal dewetting is suppressed, and film rupture is restricted to the cutting trench. We will show in this paper it is possible to generate only one droplet per gridded area on a thin film subsequent to nucleation dominated dewetting on a non-patterned substrate. Furthermore, when the grid periodicity exceeds the spinodal length, the number of droplets in predefined areas gradually approaches that associated with unconfined dewetting.

Kinetically engendered subspinodal length scales in spontaneous dewetting of thin liquid films

Numerical simulations reveal emergence of subspinodal length scales in spontaneous dewetting of nonslipping unstable thin liquid films on homogeneous substrates if the liquid viscosity decreases with decrease in film thickness.

Problematic stabilizing films in petroleum emulsions: shear rheological response of viscoelastic asphaltene films and the effect on drop coalescence

Adsorption of asphaltenes at the water-oil interface contributes to the stability of petroleum emulsions by forming a networked film that can hinder drop-drop coalescence. The interfacial microstructure can either be liquid-like or solid-like, depending on (i) initial bulk concentration of asphaltenes, (ii) interfacial aging time, and (iii) solvent aromaticity. Two techniques--interfacial shear rheology and integrated thin film drainage apparatus--provided equivalent interface aging conditions, enabling direct correlation of the interfacial rheology and droplet stability. The shear rheological properties of the asphaltene film were found to be critical to the stability of contacting drops. With a viscous dominant interfacial microstructure, the coalescence time for two drops in intimate contact was rapid, on the order of seconds. However, as the elastic contribution develops and the film microstructure begins to be dominated by elasticity, the two drops in contact do not coalescence. Such step-change transition in coalescence is thought to be related to the high shear yield stress (~10(4) Pa), which is a function of the film shear yield point and the film thickness (as measured by quartz crystal microbalance), and the increased elastic stiffness of the film that prevents mobility and rupture of the asphaltene film, which when in a solid-like state provides an energy barrier against drop coalescence.

Intrinsic viscoelasticity in thin high-molecular-weight polymer films

The rheology of 44-75-nm-thick polystyrene films were probed by destabilization in an electric field. The non-cross-linked films showed the hallmark of viscoelasiticy; they exhibited elastic behavior at high shear rates and viscous rheology at low shear rates for stationary applied fields. These results are interpreted in terms of surface adhesion of chain segments in contact with the substrate surface, which substantially reduces reptative molecular motion of nearly all chains within the film.

Wetting-dewetting films: the role of structural forces

The liquid wetting and dewetting of solids are ubiquitous phenomena that occur in everyday life. Understanding the nature of these phenomena is beneficial for research and technological applications. However, despite their importance, the phenomena are still not well understood because of the nature of the substrate's surface energy non-ideality and dynamics. This paper illustrates the mechanisms and applications of liquid wetting and dewetting on hydrophilic and hydrophobic substrates. We discuss the classical understanding and application of wetting and film stability criteria based on the Frumkin-Derjaguin disjoining pressure model. The roles of the film critical thickness and capillary pressure on the film instability based on the disjoining pressure isotherm are elucidated, as are the criteria for stable and unstable wet films. We consider the film area in the model for the film stability and the applicable experiments. This paper also addresses the two classic film instability mechanisms for suspended liquid films based on the conditions of the free energy criteria originally proposed by de Vries (nucleation hole formation) and Vrij-Scheludko (capillary waves vs. van der Waals forces) that were later adapted to explain dewetting. We include a discussion of the mechanisms of nanofilm wetting and dewetting on a solid substrate based on nanoparticles' tendency to form a 2D layer and 2D inlayer in the film under the wetting film's surface confinement. We also present our view on the future of wetting-dewetting modeling and its applications in developing emerging technologies. We believe the review and analysis presented here will benefit the current and future understanding of the wetting-dewetting phenomena, as well as aid in the development of novel products and technologies.

Rupture mechanism of liquid crystal thin films realized by large-scale molecular simulations

The ability of liquid crystal (LC) molecules to respond to changes in their environment makes them an interesting candidate for thin film applications, particularly in bio-sensing, bio-mimicking devices, and optics. Yet the understanding of the (in)stability of this family of thin films has been limited by the inherent challenges encountered by experiment and continuum models. Using unprecedented large-scale molecular dynamics (MD) simulations, we address the rupture origin of LC thin films wetting a solid substrate at length scales similar to those in experiment. Our simulations show the key signatures of spinodal instability in isotropic and nematic films on top of thermal nucleation, and importantly, for the first time, evidence of a common rupture mechanism independent of initial thickness and LC orientational ordering. We further demonstrate that the primary driving force for rupture is closely related to the tendency of the LC mesogens to recover their local environment in the bulk state. Our study not only provides new insights into the rupture mechanism of liquid crystal films, but also sets the stage for future investigations of thin film systems using peta-scale molecular dynamics simulations.

Coexistence of spinodal instability and thermal nucleation in thin-film rupture: insights from molecular levels

Despite extensive investigation using hydrodynamic models and experiments over the past decades, there remain open questions regarding the origin of the initial rupture of thin liquid films. One of the reasons that makes it difficult to identify the rupture origin is the coexistence of two dewetting mechanisms, namely, thermal nucleation and spinodal instability, as observed in many experimental studies. Using a coarse-grained model and large-scale molecular dynamics simulations, we are able to characterize the very early stage of dewetting in nanometer-thick liquid-metal films wetting a solid substrate. We observe the features characteristic of both spinodal instability and thermal nucleation in the spontaneously dewetting films and show that these two macroscopic mechanisms share a common origin at molecular levels.

Creasing-wrinkling transition in elastomer films under electric fields

Creasing and wrinkling are different types of instabilities on material surfaces characterized by localized singular folds and continuously smooth undulation, respectively. While it is known that electric fields can induce both types of instabilities in elastomer films bonded on substrates, the relation and transition between the field-induced instabilities have not been analyzed or understood. We show that the surface energy, modulus, and thickness of the elastomer determine the types, critical fields, and wavelengths of the instabilities. By independently varying these parameters of elastomers under electric fields, our experiments demonstrate transitions between creases with short wavelengths and wrinkles with long wavelengths. We further develop a unified theoretical model that accounts for both creasing and wrinkling instabilities induced by electric fields and predicts their transitions. The experimental data agree well with the theoretical model.

Squeezing instabilities and delamination in elastic bilayers: a linear stability analysis

A linear stability analysis is presented to understand the instabilities that arise in an elastic bilayer, consisting of a very thin bottom layer (thickness < 100 nm) that acts as a wetting film and a top layer that acts as an adhesive film, when placed in contact proximity with an external rigid contactor. Depending on whichever layer is more compliant, "squeezing modes" of instability with a variety of length scales ranging from <<3h to <<3h (h: bilayer thickness) are found to be possible. The least length scales obtained are 0.1h. The squeezing instabilities are, however, accompanied by delamination of the film-film interface. The instability length scales, the strength of interactions required, and the delamination decrease as the compliance of the top film increases. Surface tension effects are found to have a stabilizing influence which increases the instability length scales and decreases the degree of delamination at the cost of high interaction penalty.

Electric-field-induced interfacial instabilities of a soft elastic membrane confined between viscous layers

We explore the electric-field-induced interfacial instabilities of a trilayer composed of a thin elastic film confined between two viscous layers. A linear stability analysis (LSA) is performed to uncover the growth rate and length scale of the different unstable modes. Application of a normal external electric field on such a configuration can deform the two coupled elastic-viscous interfaces either by an in-phase bending or an antiphase squeezing mode. The bending mode has a long-wave nature, and is present even at a vanishingly small destabilizing field. In contrast, the squeezing mode has finite wave-number characteristics and originates only beyond a threshold strength of the electric field. This is in contrast to the instabilities of the viscous films with multiple interfaces where both modes are found to possess long-wave characteristics. The elastic film is unstable by bending mode when the stabilizing forces due to the in-plane curvature and the elastic stiffness are strong and the destabilizing electric field is relatively weak. In comparison, as the electric field increases, a subdominant squeezing mode can also appear beyond a threshold destabilizing field. A dominant squeezing mode is observed when the destabilizing field is significantly strong and the elastic films are relatively softer with lower elastic modulus. In the absence of liquid layers, a free elastic film is also found to be unstable by long-wave bending and finite wave-number squeezing modes. The LSA asymptotically recovers the results obtained by the previous formulations where the membrane bending elasticity is approximately incorporated as a correction term in the normal stress boundary condition. Interestingly, the presence of a very weak stabilizing influence due to a smaller interfacial tension at the elastic-viscous interfaces opens up the possibility of fabricating submicron patterns exploiting the instabilities of a trilayer.

Failure of film formation of viscoelastic fluid: dynamics of viscoelastic fluid in a partially filled horizontally rotating cylinder

The dynamics of a viscoelastic Maxwell fluid is studied in a partially filled cylinder rotating around a horizontal axis. At low rotational velocity, the fluid behaves in the same manner as a viscous fluid. A thin fluid film is pulled up from the edge of a fluid bump at the bottom of the cylinder, and it covers the inner wall of the cylinder completely. As a result, a steady state is the coexistence of the film and the bump of the fluid. When the rotational velocity of the cylinder is increased, the film formation fails and the bump of fluid rolls steadily at the bottom of the cylinder. This failure of film formation has never been observed in the case of a viscous fluid. At higher rotational velocity, the bump of the fluid starts to oscillate at the bottom of the cylinder. Then, the fluid bump again rolls steadily with a further increase in the rotational velocity. The failure of film formation is explained in terms of the elastic behavior of the viscoelastic fluid near the boundary between the film and the bump regions. The theoretical prediction shows good agreement with the experimental results. We further estimate the condition for which a viscoelastic fluid displays dynamically nonwetting behavior; i.e., the absence of fluid film at any value of rotational velocity.

Contact instabilities of anisotropic and inhomogeneous soft elastic films

Anisotropy plays important roles in various biological phenomena such as adhesion of geckos and grasshoppers enabled by the attachment pods having hierarchical structures like thin longitudinal setae connected with threads mimicked by anisotropic films. We study the contact instability of a transversely isotropic thin elastic film when it comes in contact proximity of another surface. In the present study we investigate the contact stability of a thin incompressible transversely isotropic film by performing linear stability analysis. Based on the linear stability analysis, we show that an approaching contactor renders the film unstable. The critical wavelength of the instability is a function of the total film thickness and the ratio of the Young's modulus in the longitudinal direction and the shear modulus in the plane containing the longitudinal axis. We also analyze the stability of a thin gradient film that is elastically inhomogeneous across its thickness. Compared to a homogeneous elastic film, it becomes unstable with a longer wavelength when the film becomes softer in going from the surface to the substrate.

Creating self-organized submicrometer contact instability patterns in soft elastic bilayers with a topographically patterned stamp

The surface of a thin elastic bilayer becomes spontaneously unstable when it is brought in proximity to another rigid contactor. The instability patterns, which are random and isotropic, exhibit a dominant lateral length scale of instability λ, which linearly scales with the bilayer thickness (h) as: λ = R(F)h. It is known that for an elastic bilayer, R(F) exhibits a nonlinear dependence on the ratios of individual film thicknesses (H) and shear moduli (M) of the two constituent layers, and can have values as low as 0.5 under specific conditions. This is in contrast to a near constant value of R(F) ≈ 3 for a single layer elastic film. (1) These isotropic contact instability patterns in a bilayer can be ordered, aligned and modulated using a topographically patterned stamp. The precise morphology of the aligned structures depends on commensuration between λ and the stamp periodicity (λ(P)), and on the intersurface separation distance. A variety of patterns, like an array of circular holes, double periodic channels, etc., in addition to a positive and a negative replica of the stamp pattern, can be engineered with a simple stamp having 1D grating structure. A lower value of R(F) in a bilayer allows generating patterns with sub 500 nm lateral resolution, which is impossible to create by elastic contact lithography (ECL) of a single layer film due to strong surface tension effects in ultrathin films. Thus, control of elastic instability in a bilayer with a patterned stamp represents a flexible soft lithography tool allowing modulation of length scales, morphology, and order.

Stability and dewetting of metal nanoparticle filled thin polymer films: control of instability length scale and dynamics

We investigate the influence of gold nanoparticle addition on the stability, dewetting, and pattern formation in ultrathin polymer-nanoparticle (NP) composite films by examining the length and time scales of instability, morphology, and dynamics of dewetting. For these 10-50 nm thick (h) polystyrene (PS) thin films containing uncapped gold nanoparticles (diameter approximately 3-4 nm), transitions from complete dewetting to arrested dewetting to absolute stability were observed depending on the concentration of the particles. Experiments show the existence of three distinct stability regimes: regime 1, complete dewetting leading to droplet formation for nanoparticle concentration of 2% (w/w) or below; regime 2, partial dewetting leading to formation of arrested holes for NP concentrations in the range of 3-6%; and regime 3, complete inhibition of dewetting for NP concentrations of 7% and above. Major results are (a) length scale of instability, where lambdaH approximately hn remains unchanged with NP concentration in regime 1 (n approximately 2) but increases in regime 2 with a change in the scaling relation (n approximately 3-3.5); (b) dynamics of instability and dewetting becomes progressively sluggish with an increase in the NP concentration; (c) there are distinct regimes of dewetting velocity at low NP concentrations; (d) force modulation AFM, as well as micro-Raman analysis, shows phase separation and aggregation of the gold nanoparticles within each dewetted polymer droplet leading to the formation of a metal core-polymer shell morphology. The polymer shell could be removed by washing in a selective solvent, thus exposing an array of bare gold nanoparticle aggregates.