On the coupling instability of a gas jet impinging on a liquid film

We investigate the dynamics of a gas jet impinging perpendicular to a thin liquid film dragged by a rising vertical substrate. This configuration is relevant to the jet-wiping process in hot-dip galvanization and it is unstable. Previous studies analysed the dynamics of the instability in the case of liquids with low Kapitza numbers (highly viscous liquids), more amenable to experimental and numerical investigations. This work extends the previous investigations by focusing on the wiping at much higher Kapitza numbers, which are more relevant to the galvanizing process. The simulations are carried out by combining volume of fluid and large-eddy simulations, and the dynamics of the gas–liquid interaction is analysed using extended multiscale proper orthogonal decomposition. The simulations allowed for analysing the jet-wiping instability in new flow conditions. Despite the largely different conditions, the results show that the interaction between the gas jet and the liquid film is qualitatively similar, featuring two-dimensional waves in the liquid correlated with oscillations and deflections of the gas jet in all cases. The wave characteristics (e.g. frequency and propagation speed) scale remarkably well using the Shkadov-like scaling based on the liquid, suggesting a dominant role of the liquid film in the coupling, and potentially enabling extrapolation of the results to a broader range of wiping conditions. Finally, we use the numerical results to discuss the limitations of liquid-film models, which constitute currently the only possible approach to study the jet-wiping process in industrial conditions.