Showing papers on "Liquid metal published in 2015"

Mechanically Sintered Gallium–Indium Nanoparticles

Abstract: Liquid metal nanoparticles that are mechanically sintered at and below room temperature are introduced. This material can be sintered globally on large areas of entire deposits or locally to create liquid traces within deposits. The metallic nanoparticles are fabricated by dispersing a liquid metal in a carrier solvent via sonication. The resulting dispersion is compatible with inkjet printing, a process not applicable to the bulk liquid metal in air.

Methods to pattern liquid metals

Abstract: This highlight describes emerging methods to pattern metals that are liquid at room temperature. The ability to pattern liquid metals is important for fabricating metallic components that are soft, stretchable, conformal, and in some cases, shape-reconfigurable. Applications include electrodes, antennas, micro-mirrors, plasmonic structures, sensors, switches, and interconnects. Gallium (Ga) and its liquid metal alloys are attractive alternatives to toxic mercury. This family of alloys spontaneously forms a surface oxide that dominates the rheological and wetting properties of the metal. These properties pose challenges using conventional fabrication methods, but present new opportunities for patterning innovations. For example, Ga-based liquid metals may be injected, imprinted, or 3D printed on either soft or hard substrates. The use of a liquid metal also enables rapid and facile room temperature processing. The patterning techniques organize into four categories: (i) patterning enabled by lithography, (ii) injection, (iii) subtractive techniques, and (iv) additive techniques. Although many of these approaches take advantage of the surface oxide that forms on Ga and its alloys, some of the approaches may also be suitable for patterning other soft-conductors (e.g., conductive inks, pastes, elastomeric composites).

Recapillarity: Electrochemically Controlled Capillary Withdrawal of a Liquid Metal Alloy from Microchannels

Abstract: This paper describes the mechanistic details of an electrochemical method to control the withdrawal of a liquid metal alloy, eutectic gallium indium (EGaIn), from microfluidic channels. EGaIn is one of several alloys of gallium that are liquid at room temperature and form a thin (nm scale) surface oxide that stabilizes the shape of the metal in microchannels. Applying a reductive potential to the metal removes the oxide in the presence of electrolyte and induces capillary behavior; we call this behavior “recapillarity” because of the importance of electrochemical reduction to the process. Recapillarity can repeatably toggle on and off capillary behavior by applying voltage, which is useful for controlling the withdrawal of metal from microchannels. This paper explores the mechanism of withdrawal and identifies the applied current as the key factor dictating the withdrawal velocity. Experimental observations suggest that this current may be necessary to reduce the oxide on the leading interface of the metal as well as the oxide sandwiched between the wall of the microchannel and the bulk liquid metal. The ability to control the shape and position of a metal using an applied voltage may prove useful for shape reconfigurable electronics, optics, transient circuits, and microfluidic components.

Highly Stable Liquid Metal-Based Pressure Sensor Integrated with a Microfluidic Channel

Abstract: Pressure measurement is considered one of the key parameters in microfluidic systems. It has been widely used in various fields, such as in biology and biomedical fields. The electrical measurement method is the most widely investigated; however, it is unsuitable for microfluidic systems because of a complicated fabrication process and difficult integration. Moreover, it is generally damaged by large deflection. This paper proposes a thin-film-based pressure sensor that is free from these limitations, using a liquid metal called galinstan. The proposed pressure sensor is easily integrated into a microfluidic system using soft lithography because galinstan exists in a liquid phase at room temperature. We investigated the characteristics of the proposed pressure sensor by calibrating for a pressure range from 0 to 230 kPa (R2 > 0.98) using deionized water. Furthermore, the viscosity of various fluid samples was measured for a shear-rate range of 30–1000 s−1. The results of Newtonian and non-Newtonian fluids were evaluated using a commercial viscometer and normalized difference was found to be less than 5.1% and 7.0%, respectively. The galinstan-based pressure sensor can be used in various microfluidic systems for long-term monitoring with high linearity, repeatability, and long-term stability.

Creation of Liquid Metal 3D Microstructures Using Dielectrophoresis

Abstract: Patterning customized arrays of microscale Galinstan or EGaIn liquid metals enables the creation of a variety of microfabricated systems. Current techniques for creating microsized 3D structures of liquid metals are limited by the large dimension or low aspect ratio of such structures, and time-consuming processes. Here, a novel technique for creating 3D microstructures of Galinstan using dielectrophoresis is introduced. The presented technique enables the rapid creation of Galinstan microstructures with various dimensions and aspect ratios. Two series of proof-of-concept experiments are conducted to demonstrate the capabilities of this technique. First, the 3D Galinstan microstructures are utilized as 3D microelectrodes to enhance the trapping of tungsten trioxide (WO 3 ) nanoparticles flowing through a microfluidic channel. Second, the patterned Galinstan microstructures are utilized as microfins to improve the dissipation of heat within a microfluidic channel that is located onto a hot spot. The presented technique can be readily used for creating customized arrays of 3D Galinstan microstructures for a wide range of applications. This work introduces a novel technique for creating 3D microstructures of Galinstan using dielectrophoresis. It enables the rapid formation of multiple microstructures with controllable diameters and aspect ratios. Proof-of-concept experiments are conducted by utilizing the patterned microstructures as 3D microelectrodes for enhancing the trapping of suspended nanoparticles, and as microfins to improve the convective heat transfer within a microfluidic channel.

Pressured liquid metal screen printing for rapid manufacture of high resolution electronic patterns

Abstract: In this paper, a pressured liquid metal screen printing method for rapidly manufacturing electronically conductive patterns is proposed and experimentally demonstrated. The atomized liquid metal microdroplets are pushed through the mesh openings to wet the target substrate under the airflow force. As the screen is removed away from the substrate, a liquid metal pattern is formed. The width and the thickness of the printed track can reach small values of 233.7 μm and 94.5 μm, respectively, with the surface root mean square roughness of the printed plane at 1.27 μm. With such a printing method, various kinds of complex electronic patterns such as functional circuits, general art drawings etc. can be fabricated in a short time on flexible or rigid substrates with different surface roughnesses. Durability and bending tests are performed to investigate the reliability and mechanical stability of the printed line resistors. In order to illustrate the screen printing of functional electronics, a liquid metal radio frequency identification antenna tag is fabricated with the reflection coefficient measured. Future applications of the liquid metal screen printing technique can be envisaged in flexible printed circuit board manufacturing, paper-based electronics, metal tags, the art of metal calligraphy & painting and so on.

Rapid electrocapillary deformation of liquid metal with reversible shape retention

Abstract: A low-voltage, low-power method of electrically deforming a liquid-metal droplet via the direct manipulation of its surface tension is presented. By imposing a quasi-planar geometry on the liquid metal, its sensitivity to electrocapillary actuation is increased by more than a factor of 40. This heightened responsiveness allows the liquid metal to be deformed at rates exceeding 120 mm/s, greater than an order of magnitude faster than existing techniques for electrical deformation. Significantly, it is demonstrated how this process can be combined with voltage-controlled oxide growth on the surface of non-toxic, gallium-based liquid metals to reversibly form and maintain arbitrary, high-energy shapes.

Steering liquid metal flow in microchannels using low voltages

Abstract: Liquid metals based on gallium, such as eutectic gallium indium (EGaIn) and Galinstan, have been integrated as static components in microfluidic systems for a wide range of applications including soft electrodes, pumps, and stretchable electronics. However, there is also a possibility to continuously pump liquid metal into microchannels to create shape reconfigurable metallic structures. Enabling this concept necessitates a simple method to control dynamically the path the metal takes through branched microchannels with multiple outlets. This paper demonstrates a novel method for controlling the directional flow of EGaIn liquid metal in complex microfluidic networks by simply applying a low voltage to the metal. According to the polarity of the voltage applied between the inlet and an outlet, two distinct mechanisms can occur. The voltage can lower the interfacial tension of the metal via electrocapillarity to facilitate the flow of the metal towards outlets containing counter electrodes. Alternatively, the voltage can drive surface oxidation of the metal to form a mechanical impediment that redirects the movement of the metal towards alternative pathways. Thus, the method can be employed like a 'valve' to direct the pathway chosen by the metal without mechanical moving parts. The paper elucidates the operating mechanisms of this valving system and demonstrates proof-of-concept control over the flow of liquid metal towards single or multiple directions simultaneously. This method provides a simple route to direct the flow of liquid metal for applications in microfluidics, optics, electronics, and microelectromechanical systems.

An oxidized liquid metal-based microfluidic platform for tunable electronic device applications

Abstract: Easy movement of oxidized Galinstan in microfluidic channels is a promising way for the wide application of the non-toxic liquid metal. In this paper, two different surface modification techniques (physical and chemical) are reported, which dramatically improve the non-wetting characteristics of oxidized Galinstan in the microfluidic channel. In the physical technique, normal paper textures are transferred to the inner wall of polydimethylsiloxane (PDMS) channels and four types of nanoparticles are then coated on the surface of the wall for further improvement of the non-wetting characteristics. Highest advancing angle of 167° and receding angle of 151° are achieved on the paper-textured PDMS with titanium oxide (TiO2) nanoparticles. In the chemical technique, three types of inorganic acids are employed to generate dual-scale structures on the PDMS surface. The inner wall surface treated with sulfuric acid (H2SO4) shows the highest contact angle of 167° and a low hysteresis of ~14° in the dynamic measurement. Creating, transporting, separating and merging of oxidized Galinstan droplets are successfully demonstrated in the fabricated PDMS microfluidic channels. After optimization of these modification techniques, the potential application of tunable capacitors and electronic filters is realized by using liquid metal-based microfluidic devices.

High-Speed Synchrotron X-ray Imaging Studies of the Ultrasound Shockwave and Enhanced Flow during Metal Solidification Processes

Abstract: The highly dynamic behavior of ultrasonic bubble implosion in liquid metal, the multiphase liquid metal flow containing bubbles and particles, and the interaction between ultrasonic waves and semisolid phases during solidification of metal were studied in situ using the complementary ultrafast and high-speed synchrotron X-ray imaging facilities housed, respectively, at the Advanced Photon Source, Argonne National Laboratory, US, and Diamond Light Source, UK. Real-time ultrafast X-ray imaging of 135,780 frames per second revealed that ultrasonic bubble implosion in a liquid Bi-8 wt pctZn alloy can occur in a single wave period (30 kHz), and the effective region affected by the shockwave at implosion was 3.5 times the original bubble diameter. Furthermore, ultrasound bubbles in liquid metal move faster than the primary particles, and the velocity of bubbles is 70 ~ 100 pct higher than that of the primary particles present in the same locations close to the sonotrode. Ultrasound waves can very effectively create a strong swirling flow in a semisolid melt in less than one second. The energetic flow can detach solid particles from the liquid–solid interface and redistribute them back into the bulk liquid very effectively.

Magnetic-field-induced liquid metal droplet manipulation

Abstract: We report magnetic-field-induced liquid metal droplet on-demand manipulation by coating a liquid metal with ferromagnetic materials. The gallium-based liquid metal alloy has a challenging drawback that it is instantly oxidized in ambient air, resulting in surface wetting on most surfaces. When the oxidized surface of the droplet is coated with ferromagnetic materials, it is non-wettable and can be controlled by applying an external magnetic field. We coated the surface of a liquid metal droplet with either an electroplated CoNiMnP layer or an iron (Fe) particle by simply rolling the liquid metal droplet on an Fe particle bed. For a paper towel, the minimum required magnetic flux density to initiate movement of the ~8 μL Fe-particle-coated liquid metal droplet was 50 gauss. Magnetic-field-induced liquid metal droplet manipulation was investigated under both horizontal and vertical magnetic fields. Compared to the CoNiMnP-electroplated liquid metal droplet, the Fe-particle-coated droplet could be well controlled because Fe particles were uniformly coated on the surface of the droplet. With a maximum applied magnetic flux density of ~1,600 gauss, the CoNiMnP layer on the liquid metal broke down, resulting in fragmentation of three smaller droplets, and the Fe particle was detached from the liquid metal surface and was re-coated after the magnetic field had been removed.

Visualization of Liquid Metal Two-phase Flows in a Physical Model of the Continuous Casting Process of Steel

Abstract: We present an experimental study concerned with investigations of the two-phase flow in a mock-up of the continuous casting process of steel. A specific experimental facility was designed and constructed at HZDR for visualizing liquid metal two-phase flows in the mold and the submerged entry nozzle (SEN) by means of X-ray radioscopy. This setup operates with the low melting, eutectic alloy GaInSn as model liquid. The argon gas is injected through the tip of the stopper rod into the liquid metal flow. The system operates continuously under isothermal conditions. First results will be presented here revealing complex flow structures in the SEN widely differing from a homogeneously dispersed bubbly flow. The patterns are mainly dominated by large bubbles and large-area detachments of the liquid metal flow from the inner nozzle wall. Various flow regimes can be distinguished depending on the ratio between the liquid and the gas flow rate. Smaller gas bubbles are produced by strong shear flows near the nozzle ports. The small bubbles are entrained by the submerged jet and mainly entrapped by the lower circulation roll in the mold. Larger bubbles develop by coalescence and ascend toward the free surface.

Self-Running Liquid Metal Drops that Delaminate Metal Films at Record Velocities

Abstract: This paper describes a new method to spontaneously accelerate droplets of liquid metal (eutectic gallium indium, EGaIn) to extremely fast velocities through a liquid medium and along predefined metallic paths. The droplet wets a thin metal trace (a film ∼100 nm thick, ∼ 1 mm wide) and generates a force that simultaneously delaminates the trace from the substrate (enhanced by spontaneous electrochemical reactions) while accelerating the droplet along the trace. The formation of a surface oxide on EGaIn prevents it from moving, but the use of an acidic medium or application of a reducing bias to the trace continuously removes the oxide skin to enable motion. The trace ultimately provides a sacrificial pathway for the metal and provides a mm-scale mimic to the templates used to guide molecular motors found in biology (e.g., actin filaments). The liquid metal can accelerate along linear, curved and U-shaped traces as well as uphill on surfaces inclined by 30 degrees. The droplets can accelerate through a visc...

Flexible liquid metal-filled metamaterial absorber on polydimethylsiloxane (PDMS).

Abstract: In this paper, we propose a novel flexible metamaterial (MM) absorber. The conductive pattern consists of liquid metal eutectic gallium indium alloy (EGaIn) enclosed in elastomeric microfluidic channels. Polydimethylsiloxane (PDMS) material is used as a supporting substrate. The proposed MM absorber is flexible because of its liquid metal and PDMS substrate. Numerical simulations and experimental results are presented when the microfluidic channels are filled with liquid metal. In order to evaluate the proposed MM absorber’s performance, the fabricated absorber prototype is tested with rectangular waveguides. Almost perfect absorptivity is achieved at a resonant frequency of 8.22 GHz.

Thermal convection in a liquid metal battery

Abstract: Generation of thermal convection flow in the liquid metal battery, a device recently proposed as a promising solution for the problem of the short-term energy storage, is analyzed using a numerical model. It is found that convection caused by Joule heating of electrolyte during charging or discharging is virtually unavoidable. It exists in laboratory prototypes larger than a few cm in size and should become much stronger in larger-scale batteries. The phenomenon needs further investigation in view of its positive (enhanced mixing of reactants) and negative (loss of efficiency and possible disruption of operation due to the flow-induced deformation of the electrolyte layer) effects.

Frequency-Switchable Metamaterial Absorber Injecting Eutectic Gallium-Indium (EGaIn) Liquid Metal Alloy

Abstract: In this study, we demonstrated a new class of frequency-switchable metamaterial absorber in the X-band. Eutectic gallium-indium (EGaIn), a liquid metal alloy, was injected in a microfluidic channel engraved on polymethyl methacrylate (PMMA) to achieve frequency switching. Numerical simulation and experimental results are presented for two cases: when the microfluidic channels are empty, and when they are filled with liquid metal. To evaluate the performance of the fabricated absorber prototype, it is tested with a rectangular waveguide. The resonant frequency was successfully switched from 10.96 GHz to 10.61 GHz after injecting liquid metal while maintaining absorptivity higher than 98%.

Analysis of Galinstan-Based Microgap Cooling Enhancement Using Structured Surfaces

Abstract: Analyses of microchannel and microgap cooling show that galinstan, a recently developed nontoxic liquid metal that melts at −19 °C, may be more effective than water for direct liquid cooling of electronics. The thermal conductivity of galinstan is nearly 28 times that of water. However, since the volumetric specific heat of galinstan is about half that of water and its viscosity is 2.5 times that of water, caloric, rather than convective, resistance is dominant. We analytically investigate the effect of using structured surfaces (SSs) to reduce the overall thermal resistance of galinstan-based microgap cooling in the laminar flow regime. Significantly, the high surface tension of galinstan, i.e., 7 times that of water, implies that it can be stable in the nonwetting Cassie state at the requisite pressure differences for driving flow through microgaps. The flow over the SS encounters a limited liquid–solid contact area and a low viscosity gas layer interposed between the channel walls and galinstan. Consequent reductions in friction factor result in decreased caloric resistance, but accompanying reductions in Nusselt number increase convective resistance. These are accounted for by expressions in the literature for apparent hydrodynamic and thermal slip. We develop a dimensionless expression to evaluate the tradeoff between the pressure stability of the liquid–solid–gas system and hydrodynamic slip. We also consider secondary effects including entrance effects and temperature dependence of thermophysical properties. Results show that the addition of SSs enhances heat transfer.

The Rayleigh–Plateau instability and jet formation during the extrusion of liquid metal from craters in a vacuum arc cathode spot

Abstract: We consider the displacement of molten metal from a crater being formed on the cathode during the operation of a vacuum arc under the pressure of the cathode plasma and formulate a criterion for the formation of a thin ridge of expelled liquid metal (a sheet-like jet) at the crater edge. When the ridge height is substantially greater than its thickness, conditions arise for the development of the Rayleigh–Plateau capillary instability, which breaks the axial symmetry of the problem. Estimates are presented, which suggest that this instability is responsible for the breakup of the liquid ridge into jets, which play an important role in the self-sustained operation of a discharge.

Electrochemical liquid-liquid-solid (ec-LLS) crystal growth: a low-temperature strategy for covalent semiconductor crystal growth.

Abstract: ConspectusThis Account describes a new electrochemical synthetic strategy for direct growth of crystalline covalent group IV and III–V semiconductor materials at or near ambient temperature conditions. This strategy, which we call “electrochemical liquid–liquid–solid” (ec-LLS) crystal growth, marries the semiconductor solvation properties of liquid metal melts with the utility and simplicity of conventional electrodeposition. A low-temperature liquid metal (i.e., Hg, Ga, or alloy thereof) acts simultaneously as the source of electrons for the heterogeneous reduction of oxidized semiconductor precursors dissolved in an electrolyte as well as the solvent for dissolution of the zero-valent semiconductor. Supersaturation of the semiconductor in the liquid metal triggers eventual crystal nucleation and growth. In this way, the liquid electrolyte–liquid metal–solid crystal phase boundary strongly influences crystal growth.As a synthetic strategy, ec-LLS has several intrinsic features that are attractive for pre...

Electromagnetic rotation of a liquid metal sphere or pool within a solution

Abstract: A liquid metal electric motor including a pair of concentric ring electrodes, permanent magnet and electrolyte solution is demonstrated. A liquid metal galinstan sphere, along with a NaOH solution, is stimulated to rotate centrifugally around the central electrode and the rotating speed increases with the voltage. The NaOH solution serves to rapidly remove the oxide on the liquid metal surface, reduce the motion friction and provide impetus to the liquid metal. As the mass of the liquid metal is increased to 12.16 g to form a kidney-like body, its rotating speed appears more controllable and the effect of the electrolytic action in the NaOH solution becomes weak in the range of 0–1.82 V. As the mass of the liquid metal is increased to 18.20 g to form a circular ring-shaped body, the ideal voltage range for controlling the rotating motion of the liquid metal is 0–0.81 V. The metal fluid rotates at a speed of 1.9 r.p.m., even at an extremely low voltage of 0.03 V. The liquid metal electric motor established here can find important applications in chip cooling, liquid metal pumps, material mixing, soft machine realization, etc.

Metal pad instabilities in liquid metal batteries.

Abstract: A mechanical analogy is used to analyze the interaction between the magnetic field, electric current, and deformation of interfaces in liquid metal batteries. In the framework of a low-mode, nondissipative, linear stability model, it is found that, during charging or discharging, a sufficiently large battery is prone to instabilities of two types. One is similar to the metal pad instability known to exist in the aluminum reduction cells. Another type is new. It is related to the destabilizing effect of the Lorentz force formed by the azimuthal magnetic field induced by the base current, and the current perturbations caused by the local variations of the thickness of the electrolyte layer.

Design and characterization of a single channel two-liquid capacitor and its application to hyperelastic strain sensing

Abstract: Room temperature liquid-metal microfluidic devices are attractive systems for hyperelastic strain sensing. These liquid-phase electronics are intrinsically soft and retain their functionality even when stretched to several times their original length. Currently two types of liquid metal-based strain sensors exist for in-plane measurements: single-microchannel resistive and two-microchannel capacitive devices. With a winding serpentine channel geometry, these sensors typically have a footprint of about a square centimeter. This large footprint of an individual device limits the number of sensors that can be embedded into, for example, electronic fabric or skin. In this work we introduce an alternative capacitor design consisting of two liquid metal electrodes separated by a liquid dielectric material within a single straight channel. Using a liquid insulator instead of a solid elastomer enables us to tailor the system's capacitance by selecting high or low dielectric constant liquids. We quantify the effects of the electrode geometry including the diameter, spacing, and meniscus shape as well as the dielectric constant of the insulating liquid on the overall system's capacitance. We also develop a procedure for fabricating the two-liquid capacitor within a single straight polydiemethylsiloxane channel and demonstrate that this device can have about 25 times higher capacitance per sensor's base area when compared to two-channel liquid metal capacitors. Lastly, we characterize the response of this compact device to strain and identify operational issues arising from complex hydrodynamics near liquid-liquid and liquid-elastomer interfaces.

Hydrochloric acid-impregnated paper for gallium-based liquid metal microfluidics

Abstract: We report a simple hydrochloric acid (HCl) impregnation method to substantially improve the lyophobicity of a paper against gallium-based liquid metal. Based on the HCl-impregnated paper, we also propose an extremely simple fabrication method of microfluidic channel for gallium-based liquid metal, Galinstan®. Due to its low cost, easy fabrication, and flexibility, recently paper has drawn attention as microfluidic platforms for various applications. We have treated two different types of paper (paper towel and printing paper) with various treatment methods such as laser printer flattening, fluorocarbon polymer coating, HCl-impregnation, and combination of these methods. We then studied their lyophobicity characteristics by measuring static and dynamic contact angles as well as bouncing experiment. We found that HCl-impregnation is a simple yet powerful method to engineer certain types of papers to make them super-lyophobic substrates against gallium-based liquid metals and effective for more than 30-days after impregnation. To show the feasibility, we demonstrated manipulation of a Galinstan® droplet along microfluidic channels formed on the HCl-impregnated paper.

Generation of catalytically active materials from a liquid metal precursor

Abstract: A facile route to prepare catalystically active materials from a galinstan liquid metal alloy is introduced. Sonicating liquid galinstan in alkaline solution or treating it in reducing media results in the creation of solid In/Sn rich microspheres that show catalytic activity toward both potassium ferricyanide and 4-nitrophenol reduction.

Liquid on Paper: Rapid Prototyping of Soft Functional Components for Paper Electronics

Abstract: This paper describes a novel approach to fabricate paper-based electric circuits consisting of a paper matrix embedded with three-dimensional (3D) microchannels and liquid metal. Leveraging the high electric conductivity and good flowability of liquid metal, and metallophobic property of paper, it is possible to keep electric and mechanical functionality of the electric circuit even after a thousand cycles of deformation. Embedding liquid metal into paper matrix is a promising method to rapidly fabricate low-cost, disposable, and soft electric circuits for electronics. As a demonstration, we designed a programmable displacement transducer and applied it as variable resistors and pressure sensors. The unique metallophobic property, combined with softness, low cost and light weight, makes paper an attractive alternative to other materials in which liquid metal are currently embedded.