Non-porous viscous fingering of a thin film of fluid spreading over a lubricated substrate

Viscous fingering instabilities, common in confined environments such as porous media or Hele-Shaw cells, surprisingly also occur in unconfined, non-porous settings as revealed by recent experiments. These novel instabilities involve free-surface flows of dissimilar viscosity. We demonstrate that such a free-surface flow, involving a thin film of viscous fluid spreading over a substrate that is prewetted with a fluid of higher viscosity, is susceptible to a similar type of novel viscous fingering instability. Such flows are relevant to a range of geophysical, industrial and physiological applications from the small scales of thin-film coating applications and nasal drug delivery to the large scales of lava flows. In developing a theoretical framework, we assume that the intruding layer and the liquid film over which it flows are both long and thin, the effects of inertia and surface tension are negligible, and both layers are driven by gravity and resisted by viscous shear stress so that the principles of lubrication theory hold. We investigate the stability of axisymmetric similarity solutions, describing the base flow, by examining the growth of small-amplitude non-axisymmetric perturbations. We characterise regions of instability across parameter space and find that these instabilities emerge above a critical viscosity ratio. That is, a fluid of low viscosity intruding into another fluid of sufficiently high viscosity is susceptible to instability, akin to traditional viscous fingering in a porous medium. We identify the mechanism of instability, compare with other frontal instabilities and demonstrate that high enough density differences suppress the instability completely.