Showing papers on "Liquid metal published in 2016"

Ionic imbalance induced self-propulsion of liquid metals

Abstract: Components with self-propelling abilities are important building blocks of small autonomous systems and the characteristics of liquid metals are capable of fulfilling self-propulsion criteria. To date, there has been no exploration regarding the effect of electrolyte ionic content surrounding a liquid metal for symmetry breaking that generates motion. Here we show the controlled actuation of liquid metal droplets using only the ionic properties of the aqueous electrolyte. We demonstrate that pH or ionic concentration gradients across a liquid metal droplet induce both deformation and surface Marangoni flow. We show that the Lippmann dominated deformation results in maximum velocity for the self-propulsion of liquid metal droplets and illustrate several key applications, which take advantage of such electrolyte-induced motion. With this finding, it is possible to conceive the propulsion of small entities that are constructed and controlled entirely with fluids, progressing towards more advanced soft systems.

Fabrication methods and applications of microstructured gallium based liquid metal alloys

Abstract: This review contains a comparative study of reported fabrication techniques of gallium based liquid metal alloys embedded in elastomers such as polydimethylsiloxane or other rubbers as well as the primary challenges associated with their use. The eutectic gallium–indium binary alloy (EGaIn) and gallium–indium–tin ternary alloy (galinstan) are the most common non-toxic liquid metals in use today. Due to their deformability, non-toxicity and superior electrical conductivity, these alloys have become very popular among researchers for flexible and reconfigurable electronics applications. All the available manufacturing techniques have been grouped into four major classes. Among them, casting by needle injection is the most widely used technique as it is capable of producing features as small as 150 nm width by high-pressure infiltration. One particular fabrication challenge with gallium based liquid metals is that an oxide skin is rapidly formed on the entire exposed surface. This oxide skin increases wettability on many surfaces, which is excellent for keeping patterned metal in position, but is a drawback in applications like reconfigurable circuits, where the position of liquid metal needs to be altered and controlled accurately. The major challenges involved in many applications of liquid metal alloys have also been discussed thoroughly in this article.

Liquid metal actuation by electrical control of interfacial tension

Abstract: By combining metallic electrical conductivity with low viscosity, liquid metals and liquid metal alloys offer new and exciting opportunities to serve as reconfigurable components of electronic, microfluidic, and electromagnetic devices. Here, we review the physics and applications of techniques that utilize voltage to manipulate the interfacial tension of liquid metals; such techniques include electrocapillarity, continuous electrowetting, electrowetting-on-dielectric, and electrochemistry. These techniques lower the interfacial tension between liquid metals and a surrounding electrolyte by driving charged species (or in the case of electrochemistry, chemical species) to the interface. The techniques are useful for manipulating and actuating liquid metals at sub-mm length scales where interfacial forces dominate. We focus on metals and alloys that are liquid near or below room temperature (mercury, gallium, and gallium-based alloys). The review includes discussion of mercury—despite its toxicity—because it has been utilized in numerous applications and it offers a way of introducing several phenomena without the complications associated with the oxide layer that forms on gallium and its alloys. The review focuses on the advantages, applications, opportunities, challenges, and limitations of utilizing voltage to control interfacial tension as a method to manipulate liquid metals.

Liquid-Metal Microdroplets Formed Dynamically with Electrical Control of Size and Rate

Abstract: Liquid metal co-injected with electrolyte through a microfluidic flow-focusing orifice forms droplets with diameters and production frequencies controlled in real time by voltage. Applying voltage to the liquid metal controls the interfacial tension via a combination of electrochemistry and electrocapillarity. This simple and effective method can instantaneously tune the size of the microdroplets, which has applications in composites, catalysts, and microsystems.

An Integrated Liquid Cooling System Based on Galinstan Liquid Metal Droplets.

Abstract: The continued miniaturization of electronic components demands integrated liquid cooling systems with minimized external connections and fabrication costs that can be implanted very close to localized hot spots. This might be challenging for existing liquid cooling systems because most of them rely on external pumps, connecting tubes, and microfabricated heat sinks. Here, we demonstrate an integrated liquid cooling system by utilizing a small droplet of liquid metal Galinstan, which is placed over the hot spot. Energizing the liquid metal droplet with a square wave signal creates a surface tension gradient across the droplet, which induces Marangoni flow over the surface of droplet. This produces a high flow rate of coolant medium through the cooling channel, enabling a “soft” pump. At the same time, the high thermal conductivity of liquid metal extends the heat transfer surface and facilitates the dissipation of heat, enabling a “soft” heat sink. This facilitates the rapid cooling of localized hot spots,...

On-Chip Production of Size-Controllable Liquid Metal Microdroplets Using Acoustic Waves.

Abstract: Micro- to nanosized droplets of liquid metals, such as eutectic gallium indium (EGaIn) and Galinstan, have been used for developing a variety of applications in flexible electronics, sensors, catalysts, and drug delivery systems. Currently used methods for producing micro- to nanosized droplets of such liquid metals possess one or several drawbacks, including the lack in ability to control the size of the produced droplets, mass produce droplets, produce smaller droplet sizes, and miniaturize the system. Here, a novel method is introduced using acoustic wave-induced forces for on-chip production of EGaIn liquid-metal microdroplets with controllable size. The size distribution of liquid metal microdroplets is tuned by controlling the interfacial tension of the metal using either electrochemistry or electrocapillarity in the acoustic field. The developed platform is then used for heavy metal ion detection utilizing the produced liquid metal microdroplets as the working electrode. It is also demonstrated that a significant enhancement of the sensing performance is achieved by introducing acoustic streaming during the electrochemical experiments. The demonstrated technique can be used for developing liquid-metal-based systems for a wide range of applications.

Self-Actuation of Liquid Metal via Redox Reaction.

Abstract: Presented here is a method for actuating a gallium-based liquid-metal alloy without the need for an external power supply. Liquid metal is used as an anode to drive a complementary oxygen reduction reaction, resulting in the spontaneous growth of hydrophilic gallium oxide on the liquid-metal surface, which induces flow of the liquid metal into a channel. The extent and duration of the actuation are controllable throughout the process, and the induced flow is both reversible and repeatable. This self-actuation technique can also be used to trigger other electrokinetic or fluidic mechanisms.

Self-Regulated Plasma Heat Flux Mitigation Due to Liquid Sn Vapor Shielding

Abstract: A steady-state high-flux H or He plasma beam was balanced against the pressure of a Sn vapor cloud for the first time, resulting in a self-regulated heat flux intensity near the liquid surface. A temperature response of the liquid surface characterized by a decoupling from the received heating power and significant cooling of the plasma in the neutral Sn cloud were observed. The plasma heat flux impinging on the target was found to be mitigated, as heat was partially dissipated by volumetric processes in the vapor cloud rather than wholly by surface effects. These results motivate further exploration of liquid metal solutions to the critical challenge of heat and particle flux handling in fusion power plants.

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 centimeters 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.

Development of an oxide-dispersion-strengthened steel by introducing oxygen carrier compound into the melt aided by a general thermodynamic model.

Abstract: In general, melting process is not a common method for the production of oxide dispersion strengthened (ODS) alloys due to agglomeration and coarsening of oxide particles. However, vacuum casting process has recently been employed as a promising process to produce micro-scale oxide dispersed alloys. In this paper, we report the process and characterization of in situ formation and uniform dispersion of nano-scale Y-Ti oxide particles in Fe-10Ni-7Mn (wt.%) alloy. The processing route involves a solid-liquid reaction between the added TiO2 as an oxygen carrier and dissolved yttrium in liquid metal leading to an optimal microstructure with nano-sized dispersed oxide particles. The developed thermodynamic model shows the independence of the final phase constituents from experimental conditions such as melting temperature or vacuum system pressure which offers a general pathway for the manufacture of oxide dispersion strengthened materials.

Impact-driven ejection of micro metal droplets on-demand

Abstract: On-demand metal droplet deposition will be a cornerstone technology in 3D metal printing. However, suitable small nozzles are hardly available, limiting the resolution and surface finish of final products. Here, the ejection of record-small metal droplets with a diameter of only 0.55±0.07 times the nozzle diameter was demonstrated. To this end, a novel metal drop-on-demand (DoD) generator for high-temperature metal processing was designed and manufactured. A metal rod was utilized to transfer a vibration pulse, which was required to eject a liquid droplet, from a low-temperature region to the high-temperature liquid metal close to the nozzle. The influence of the pulse characteristics on the droplet ejection regime was studied experimentally and numerically. A 2D axisymmetric numerical model revealed that the shorter pulses allow reducing the droplet size, with the pulse duration of 13 μs resulting in the smallest feasible droplets. A novel method to create such short pulses, by impacting the metal-ring connected rod with a solid impactor was manufactured and tested, and the benefits of this method over more the spring-type pulse transfer was experimentally confirmed. This research provides a feasible way to achieve ejection of the small metal droplet on-demand

Alternating electric field actuated oscillating behavior of liquid metal and its application

Abstract: As a class of newly emerging functional material, Gallium based liquid metals have attracted increasing attentions in many fields, such as chip cooling, printed electronics and microfluidics, etc. Particularly, the motion control of liquid metal droplet has been recently tried for its importance in microelectromechanical system (MEMS), microfluidics and potential use in micro-machine or reconfigurable soft robot. This paper is dedicated to explore the motion behavior of liquid metal droplet under AC electric field. The quickly induced oscillation phenomena of liquid metal droplet and surrounding electrolyte solution were observed and the major factors to influence such behaviors are theoretically interpreted and experimentally investigated, including the size of the liquid metal droplet, electrode voltage, electrolyte solution concentration and AC signal frequency etc. Moreover, some typical features to distinguish AC filed actuation with DC field are observed, such as intensive fluid waving induced by the resonance stimulation, and the efficient inhibition of solution electrolysis. Finally, two important applications of adopting AC induced surface oscillation of liquid metal droplet to develop solution mixer as well as fluidic pump were demonstrated which successfully avoid gas generation inside electrolyte environment. The bulk oscillation effects of liquid metal as clarified here could be very useful in a variety of areas such as solution disturbance and mixing, and fluid oscillator or pump etc.

Microstructure, fracture toughness and compressive property of as-cast and directionally solidified NiAl-based eutectic composite

Abstract: Microstructure and room temperature mechanical property of as-cast and directionally solidified NiAl-Cr(Mo) eutectic composite were investigated by SEM, EDS, three point bending test and compression test. The microstructure of as-cast alloy consists of Cr(Mo) primary dendrites and equiaxed eutectic cells. For the directional solidification of liquid metal cooling technique (LMC), only the small quantity of Cr(Mo) primary dendrites appear in the beginning of solidification, and the fully and well-aligned lamellar structure parallel to the growth direction is obtained in the steady-state zone. However, the Cr(Mo) primary phase is always observed in the whole directional solidification of zone melted liquid metal cooling technique (ZMLMC), and the eutectic lamellas are disordered and not parallel to the growth direction in the steady-state zone. Compared to the ZMLMC alloys, the LMC alloy has the better room temperature fracture toughness and compressive property due to the well-aligned lamellar structure. Crack propagation and fracture surface are also observed to understand the fracture behavior.

Electrically driven chip cooling device using hybrid coolants of liquid metal and aqueous solution

Abstract: Heat dissipation of electronic devices keeps as a tough issue for decades. As the most classical coolant in a convective heat transfer process, water has been widely adopted which however inherits with limited thermal conductivity and relies heavily on mechanical pump. As an alternative, the room temperature liquid metal was increasingly emerging as an important coolant to realize much stronger enhanced heat transfer. However, its thermal capacity is somewhat lower than that of water, which may restrict the overall cooling performance. In addition, the high cost by taking too much amount of liquid metal into the device also turns out to be a big concern for practical purpose. Here, through combining the individual merits from both the liquid metal with high conductivity and water with large heat capacity, we proposed and demonstrated a new conceptual cooling device that integrated hybrid coolants, radiator and annular channel together for chip thermal management. Particularly, the electrically induced actuation effect of liquid metal was introduced as the only flow driving strategy, which significantly simplified the whole system design. This enables the liquid metal sphere and its surrounding aqueous solution to be quickly accelerated to a large speed under only a very low electric voltage. Further experiments demonstrated that the cooling device could effectively maintain the temperature of a hotpot (3.15 W/cm2) below 55oC with an extremely small power consumption rate (0.8 W). Several situations to simulate the practical working of the device were experimentally explored and a theoretical thermal resistance model was established to evaluate its heat transfer performance. The present work suggests an important way to make highly compact chip cooling device, which can be flexibly extended into a wide variety of engineering areas.

Breathing to harvest energy as a mechanism towards making a liquid metal beating heart

Abstract: Simulating nature to manufacture a self-powered device or motor has been an important goal in science and engineering. Conventional spontaneous motion has generally been achieved through the Marangoni flow of an organic liquid or water solution. Moreover, as a metallic material mercury has been developed as a beating heart, a kind of self-propulsion example. However, serious safety concerns about mercury restrict its extensive application. This study discovered an important mechanism to realize a GaIn alloy-based liquid metal beating heart by introducing a breathing mechanism in simulating living organisms. With the unique configuration of a semi-submerged liquid metal droplet partially immersed in alkaline solution, such a system produces a surface tension gradient perpendicular to the three-phase contact line which subsequently leads to the oscillation of the droplet and the surrounding solution. This finding suggests a feasible way to fabricate self-oscillating liquid metal motors without input of external electricity or fuels.

Bifilm defects and porosity in Al cast alloys

Abstract: Liquid Al and Mg-base alloys are so reactive that it is reasonable to assume that the surface layer is always oxidized. If liquid aluminium entered a mould cavity with a velocity greater than a critical value, the surface skin of the liquid metal would fold over onto itself and be submerged into the bulk liquid with a volume of air entrapped within it, creating what is called a bifilm defect. This defect not only acts as a crack but also it is recognized to initiate hydrogen porosity in the solidified casting, which has been found to have detrimental effects on the tensile and fatigue properties of the castings produced. Previous research suggested that during solidification, the hydrogen, in excess of the solubility limit, comes out of the solution and diffuses into the bifilm gap, expanding it into a pore. Also, placing liquid metal in a vacuum may cause its entrained bifilms to expand, enhancing their buoyancy and therefore their floatation to the surface of the melt. In this work, a casting from an A356 Al alloy was allowed to solidify under vacuum. The solidified casting was sectioned into two halves, and the internal surfaces of the pores were investigated using an SEM to determine their relationship with double oxide film defects.

Magnetic Liquid Metal Marble: Characterization of Lyophobicity and Magnetic Manipulation for Switching Applications

Abstract: We report a “magnetic liquid metal marble” (MLMM) obtained by coating a liquid metal’s surface with micro/nano-sized ferromagnetic iron (Fe) particles, which enables on-demand, magnetic manipulation of a liquid metal droplet for switching applications. Among liquid metals, gallium-based liquid metal alloys have been developed for a variety of applications. However, most developed applications using the gallium-based liquid metal alloy only work on deformability because of its easy-wetting property stemming from surface oxidation. By coating the oxidized surface with the 45 $\mu \text{m}$ or 45 nm diameter Fe particles, the MLMM exhibits non-wetting property investigated by evaluating apparent contact angles and sliding angles against various surfaces. On the Teflon-coated glass, the largest contact angle was measured to be ~169.0°, and the lowest sliding angle was obtained to be 17.2°, respectively. In order to move the 45- $\mu \text{m}$ diameter Fe particles-coated MLMM, we measured the minimum required magnetic flux density of 150 gauss and demonstrated the magnetic control of the liquid metal marble to turn ON light emitting diodes. In addition, we investigated that hydrochloric acid-vapor treatment on the MLMM enhanced the lyophobicity (sliding angle of 9.4°), reduced the minimum magnetic flux density (150 to 107 gauss) to actuate it, and enabled electrical switching applicability even in silicon oil with shorter delay time and high mobility of the MLMM under the applied magnetic field. [2015-0329]

Modeling of the anode surface deformation in high-current vacuum arcs with AMF contacts

Abstract: A high-current vacuum arc subjected to an axial magnetic field is maintained in a diffuse status. With an increase in arc current, the energy carried by the arc column to the anode becomes larger and finally leads to the anode temperature exceeding the melting point of the anode material. When the anode melting pool is formed, and the rotational plasma of the arc column delivers its momentum to the melting pool, the anode melting pool starts to rotate and also flow outwards along the radial direction, which has been photographed by some researchers using high-speed cameras. In this paper, the anode temperature and melting status is calculated using the melting and solidification model. The swirl flow of the anode melting pool and deformation of the anode is calculated using the magneto-hydrodynamic (MHD) model with the volume of fraction (VOF) method. All the models are transient 2D axial-rotational symmetric models. The influence of the impaction force of the arc plasma, electromagnetic force, viscosity force, and surface tension of the liquid metal are all considered in the model. The heat flux density injected into the anode and the arc pressure are obtained from the 3D numerical simulation of the high-current vacuum arc using the MHD model, which gives more realistic parameters for the anode simulation. Simulation results show that the depth of the anode melting pool increases with an increase in the arc current. Some droplets sputter out from the anode surface, which is caused by the inertial centrifugal force of the rotational melting pool and strong plasma pressure. Compared with the previous anode melting model without consideration of anode deformation, when the deformation and swirl flow of the anode melting pool are considered, the anode temperature is relatively lower, and just a little more than the melting point of Cu. This is because of liquid droplets sputtering out of the anode surface taking much of the energy away from the anode surface. The azimuthal velocity of the anode melting pool for arc current 12.5 kA root-mean-square (rms) is larger than that for 17.5 kA (rms), which is likely to be caused by the thinner liquid layer, and also a smaller melting pool mass of 12.5 kA.

Free surface stability of liquid metal plasma facing components

Abstract: An outstanding concern raised over the implementation of liquid metal plasma facing components in fusion reactors is the potential for ejection of liquid metal into the fusion plasma. The influences of Rayleigh–Taylor-like and Kelvin–Helmholtz-like instabilities were experimentally observed and quantified on the thermoelectric-driven liquid-metal plasma-facing structures (TELS) chamber at the University of Illinois at Urbana–Champaign. To probe the stability boundary, plasma currents and velocities were first characterized with a flush probe array. Subsequent observations of lithium ejection under exposure in the TELS chamber exhibited a departure from previous theory based on linear perturbation analysis. The stability boundary is mapped experimentally over the range of plasma impulses of which TELS is capable to deliver, and a new theory based on a modified set of the shallow water equations is presented which accurately predicts the stability of the lithium surface under plasma exposure.