A Mathematical Model for Crater Defect Formation in a Drying Paint Layer

Certain deep indentations observed in dry coatings are referred to as “craters”. They are believed to arise from gradients in the coating surface tension. A mathematical model of surface-tension-gradient-driven flow, using the lubrication approximation for thin layers, is developed to study the formation of craters. The paint is modeled as consisting of an evaporating “solvent” part and a nonvolatile “resin” part. Surface tension gradients on the coating surface arise due to a nonuniform distribution of surfactant. Axisymmetric numerical simulations using the model are performed to explore two candidate crater production mechanisms: an initial release of concentrated surfactant and a steady surfactant source. The effects of changes in various properties, such as the paint drying rate, the surfactant diffusivity, and the viscosity increase during drying, are examined. The model produces craters with large diameters, pronounced rims, and central peaks, similar to those seen in practice. Drying rate has a large influence on crater diameter and depth, by limiting flow due to surface tension gradients within a given time. Reduction of the paint viscosity increase during drying causes increased flow rates, leading to larger craters. A preexisting layer of surfactant on the paint surface sharply reduces the extent of cratering. Surfactant diffusion also tends to reduce the severity of cratering by alleviating surface tension gradients. In some cases, a simplified form of the drying model may be used to quickly approximate the results of the full model. The model provides useful insights into the craters seen in industrial coating applications.