The convective drying of liquid films on slender wires

We solve numerically the balance equations of mass and thermal energy for drying liquid films of binary solutions on cylindrical substrates to simulate the drying process of liquid coatings on round metal wires, which are used for electrical insulation in magnet wire technology. The liquid phase diffusion coefficient and the solvent activity are treated as concentration and temperature dependent. The evaporation rate of the solvent across the shrinking liquid–gas interface is determined using the film theory, accounting for the thermodynamic state of the ambient medium and the convective flow situation. The quality of the coatings is assessed by the temporal evolution of radial profiles of the solute mass fraction and by detecting boiling, which leads to the formation of vapour bubbles in the liquid films and is undesired. A guideline for uniform drying at various drying conditions is presented. The simulation model is applied to the test system PVA-water.