The nonlinear electrohydrodynamic (EHD) instability of a circular cylindrical interface, separating two Casson prototypes is the aim of the present inspection. The motivation for the issue is owing to the increasing significance of several engineering and practicle physics. Because of the complicated mathematical processes, the contribution is performed through the viscous potential theory (VPT). The methodology resulted in a nonlinear characteristic equation of the interface displacement. This equation is transformed to simulate a hybrid Rayleigh-Helmholtz Duffing oscillator (HRDO) with complex coefficients. Guaranteeing the stability of fluid interfaces is crucial in industrial coating operations to provide consistent and even coatings. Gaining comprehension of the nonlinear stability criterion helps to enhance the management of coating thickness and uniformity. A novel methodology via the Non-perturbative approach (NPA) is employed. Through the case of the real coefficients, the later form is validated using a numerical solution (NS). It is concluded that the Ohnesorge contribution has a destabilizing effect on the stability zone in contrast with permeability factor. The electrical coefficients are found to be decaying factors in the stability configuration. It is also established that the viscosity decays the nonlinear steadiness requirement of the structure. The approach is a simple, promising, effective, and interesting.
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