Pattern formation and dewetting in thin films of liquids showing complete macroscale wetting: from "pancakes"to "swiss cheese".

Based on the complete 3D numerical solutions of the nonlinear thin film equation, we address the problems of surface instability, dynamics, morphological diversity and evolution in unstable thin films of the liquids that display complete macroscale wetting. The twin constraints of complete macroscale wettability and nanoscale instability produce a variety of microscopic morphological phases approximating sharp crystal surfaces with flat tops resembling a mesa or a micro "pancake" or a slice of Swiss cheese. While the maximum thickness of flat regions is found to be independent of the initial film thickness, the precise lateral morphology of microdomains formed depends on the film thickness. As the film thickness is increased, the initial pathway of evolution changes from the formation of small spherical droplets, to long mesas (parapets) and islands, to circular holes, all of which eventually resolve by ripening into a collection of round pancakes at equilibrium. However, beyond a certain transition thickness, a novel metastable honeycombed morphology, resembling a membrane or a slice of Swiss cheese, is uncovered, which is produced by an abrupt "freezing" of the evolution during hole growth. In contrast, the spinodal dewetting in thin films of partially wettable systems always engenders spherical droplets at equilibrium. The equilibrium dewetted area from simulations, as well as from simple mass balance, is shown to decline linearly with the initial film thickness.