An Integrated Liquid Cooling System Based on Galinstan Liquid Metal Droplets

Production and recycling of the cutting edge material of gallium: A review

Gallium, an indispensable scattering element, is driving the development of an array of latest generation functional materials. Due to its exceptionally conductive, fluidic, thermal, flexible, and biocompatible attributes, gallium and its derivatives are increasingly introduced into diverse cutting edge industries. Meanwhile, the aggravated irreconcilable contradiction between the rapid growth of gallium consumption and the severe shortage of gallium resources also brings about big concern regarding its availability for the coming era. In this review, we conducted a comprehensive examination on the global distribution and reserves of gallium which indicates sporadic locations and low concentrations of gallium, highlighting the daunting challenge of extracting gallium. Following that, extensive assessments of gallium production and recovery treatments were presented, ranging from ore mining to high-purity gallium extraction, from major to minor production methods, and from primary gallium extraction to recycling gallium reclamation. Finally, based on evaluating ongoing trends over the field, a forecast of the future gallium production and recycling was given. Potential barriers and their corresponding mitigation strategies were interpreted.

An enhanced heat transfer method based on the electrocapillary effect of gallium-based liquid metal

As electronic products become smaller and more powerful, there is an increasing need for effective heat dissipation. An effective heat exchange method is necessary for the equipment to function reliably in a compact space. To tackle the limitations of current microfluidic cooling technology, including difficulty in manufacturing, maintenance, and cost reduction, a heat exchange method with a simple system is proposed in this work. This method is based on the electrocapillary effect, using eutectic gallium-indium alloy droplets with high thermal conductivity, surface tension, and controllability as the basic unit. An electric field is applied to generate unevenly distributed charges in the electric double layer on the droplet surface, thereby creating a surface tension gradient that can drive the surrounding solution to flow. Simultaneously, the oscillation of the droplet can also intensify the disturbance of the solution. The violent disturbance of the solution causes the heat transfer mode to change from conduction to convective heat transfer and greatly reduces the thermal resistance, resulting in a substantial increase in heat flux. For this heat transfer method, the temperature distribution and flow characteristics of the solution in low-frequency oscillating and direct-current-biased alternating current electric fields are studied, and the effect of voltage, frequency, and the number of droplets on heat transfer enhancement is clarified. Compared with conduction without internal disturbance, the heat flux can be increased by up to 110% based on the combined effect of two droplets. This work provides a solution for enhancing the heat transfer of microfluidics.

Synthesis and analysis of a novel thermal interface material for DC-DC boost converter

The rapid evolution of power electronics has triggered an intensified focus on thermal management within electronics circuits, stemming from the critical necessity to mitigate thermal-related failure rates. Thermal management in power electronics circuits relies heavily on efficient heat transfer to prevent overheating of components and ensure their reliable operation, optimal performance, and safety. To facilitate the effective heat transfer, a thermal interface material (TIM) is utilized between switching components such as MOSFETs and heat sinks to improve surface contact, which increases heat transfer. In this research work, a novel thermal interface material (TIM) based on Tungsten-Gallium is introduced and evaluated to enhance thermal properties such as thermal conductivity and viscosity of Gallium-based TIM material with the addition of Tungsten microparticles. The study involves the examination of three distinct TIM samples with varying Tungsten content. Their surface morphology, composition, and topography were analyzed through techniques such as Scanning Electron Microscopy (SEM) and Atomic Force Microscopy (AFM) within the context of a DC-DC boost converter. The results indicate that the addition of Tungsten significantly enhances TIM's viscosity and fluidity, even at high temperatures reaching up to 308 °C, which is crucial for power electronics circuits. In addition, thermal constant analyzer, and DC-DC converter circuit such as boost converter circuit were utilized for thermal and electrical characterization, respectively. These characterization results demonstrate that 10%/wt. addition of Tungsten can increase the thermal conductivity of Gallium from 13.1 to 22.82 W/m.K at room temperature, which represents an overall 74.2% increase in thermal conductivity. Furthermore, when the proposed TIM sample 2 was used in a boost converter circuit, the switching frequency of MOSFET IRF3808 was increased up to 20 kHz while the conduction losses were also lowest compared to other TIM samples.

Gallium-based liquid metals as smart responsive materials: Morphological forms and stimuli characterization

Gallium-based liquid metals (GaLMs) have garnered monumental attention from the scientific community due to their diverse actuation characteristics. These metals possess remarkable characteristics, including high surface tension, excellent electrical and thermal conductivity, phase transformation behaviour, minimal viscosity and vapour pressure, lack of toxicity, and biocompatibility. In addition, GaLMs have melting points that are either lower or near room temperature, making them incredibly beneficial when compared to solid metals since they can be easily deformed. Thus, there has been significant progress in developing multifunctional devices using GaLMs, including bio-devices, flexible and self-healing circuits, and actuators. Despite numerous reports on these liquid metals (LMs), there is an urgent need for consolidated and coherent literature regarding their actuation principles linked to the targeted application. This will ensure that the reader gets the flavour of physics behind the actuation mechanism and how it can be utilized in diverse fields. Moreover, the actuation mechanism has been scattered in the literature, and thus, the primary motive of this review is to provide a one-stop solution for the actuation mechanism and the associated dynamics while directing the readers to specialized literature. Thus, addressing this issue, we thoroughly examine and present a detailed account of the actuation mechanisms of GaLMs while highlighting the science behind them. We also discuss the various morphologies of GaLMs and their crucial physical characteristics which decide their targeted application. Furthermore, we also delve into commonly held beliefs about GaLMs in the literature, such as their toxicity and antibacterial properties, to offer readers a more accurate understanding. Finally, we have explored several key unanswered aspects of the LM that should be explored in future research. The core strength of this review lies in its simplistic approach in offering a starting point for researchers venturing this innovative field, while we make use of existing literature to develop a comprehensive understanding.

Recent progress in multifunctional, reconfigurable, integrated liquid metal-based stretchable sensors and standalone systems

Possessing a unique combination of properties that are traditionally contradictory in other natural or synthetical materials, Ga-based liquid metals (LMs) exhibit low mechanical stiffness and flowability like a liquid, with good electrical and thermal conductivity like metal, as well as good biocompatibility and room-temperature phase transformation. These remarkable properties have paved the way for the development of novel reconfigurable or stretchable electronics and devices. Despite these outstanding properties, the easy oxidation, high surface tension, and low rheological viscosity of LMs have presented formidable challenges in high-resolution patterning. To address this challenge, various surface modifications or additives have been employed to tailor the oxidation state, viscosity, and patterning capability of LMs. One effective approach for LM patterning is breaking down LMs into microparticles known as liquid metal particles (LMPs). This facilitates LM patterning using conventional techniques such as stencil, screening, or inkjet printing. Judiciously formulated photo-curable LMP inks or the introduction of an adhesive seed layer combined with a modified lift-off process further provide the micrometer-level LM patterns. Incorporating porous and adhesive substrates in LM-based electronics allows direct interfacing with the skin for robust and long-term monitoring of physiological signals. Combined with self-healing polymers in the form of substrates or composites, LM-based electronics can provide mechanical-robust devices to heal after damage for working in harsh environments. This review provides the latest advances in LM-based composites, fabrication methods, and their novel and unique applications in stretchable or reconfigurable sensors and resulting integrated systems. It is believed that the advancements in LM-based material preparation and high-resolution techniques have opened up opportunities for customized designs of LM-based stretchable sensors, as well as multifunctional, reconfigurable, highly integrated, and even standalone systems.

A system for fluid pumping by liquid metal multi-droplets

The transportation and control of microfluidics have an important influence on the fields of biology, chemistry, and medicine. Pump systems based on the electrocapillary effect and room-temperature liquid metal droplets have attracted extensive attention. Flow rate is an important parameter that reflects the delivery performance of the pump systems. In the systems of previous studies, cylindrical structures are mostly used to constrain the droplet. The analysis and quantitative description of the influence of voltage frequency, alternating voltage, direct current voltage bias, and solution concentration on the flow rate are not yet comprehensive. Furthermore, the systems are driven by only one droplet, which limits the increase in flow rate. Therefore, a pump with a cuboid structure is designed and the droplet is bound by pillars, and the flow rate of the pump is increased by more than 200% compared with the cylindrical pump. For this structure, the mechanism of various factors on the flow rate is analyzed. To further enhance the flow rate, a pump system with multi-droplets is proposed. Moreover, the expression of flow velocity of the solution on the surface of each droplet and the relationship between the flow rate, alternating voltage, and the number of droplets are deduced. Finally, the potential of applying the multi-droplet cuboid pump system in drug delivery and analytical chemistry is demonstrated. Additionally, the core of the pump, the droplet area, is modularized, which breaks the overall structural limitations of the liquid metal pump and provides ideas for pump design.

Homogeneity of liquid metal polymer composites: impact on mechanical, electrical, and sensing behavior

Liquid metal polymer composites (LMPCs) are formed by dispersing eutectic gallium-indium-tin (galinstan) droplets within a soft polymer matrix, such as polydimethylsiloxane (PDMS), resulting in an insulating composite that is suitable for dielectric applications, including wearable sensors and actuators. LMPCs offer a unique combination of robust mechanical performance and desirable electrical properties. While much research has focused on the effects of rigid fillers in polymer composites, the behavior of liquid metal fillers, particularly the impact of homogeneity, has received limited attention. The density disparity between galinstan and the polymer matrix (6.44 g cm-3 compared to 0.97 g cm-3) results in the settling of galinstan droplets before curing, especially in matrices with low viscosity, leading to an inhomogeneous composition that may affect material performance. To address this, an innovative approach was introduced that enabled a spatially uniform (homogeneous) dispersion of galinstan droplets in PDMS while preserving the non-conductive nature of the composites. Work described herein evaluates the influence of homogeneity on electrical and mechanical properties as well as performance of LMPCs as pressure sensors. It was found that homogeneity has minimal effect on permittivity and dielectric loss but exhibits a complex behavior with respect to other parameters, including dielectric strength, which is often exacerbated at higher concentrations (≥50 vol%). These findings provide valuable insight that contributes to improved control over the material properties of LMPCs and expands their potential applications in soft robotics and stretchable electronics.

Recent progress in fiber-based soft electronics enabled by liquid metal

Soft electronics can seamlessly integrate with the human skin which will greatly improve the quality of life in the fields of healthcare monitoring, disease treatment, virtual reality, and human-machine interfaces. Currently, the stretchability of most soft electronics is achieved by incorporating stretchable conductors with elastic substrates. Among stretchable conductors, liquid metals stand out for their metal-grade conductivity, liquid-grade deformability, and relatively low cost. However, the elastic substrates usually composed of silicone rubber, polyurethane, and hydrogels have poor air permeability, and long-term exposure can cause skin redness and irritation. The substrates composed of fibers usually have excellent air permeability due to their high porosity, making them ideal substrates for soft electronics in long-term applications. Fibers can be woven directly into various shapes, or formed into various shapes on the mold by spinning techniques such as electrospinning. Here, we provide an overview of fiber-based soft electronics enabled by liquid metals. An introduction to the spinning technology is provided. Typical applications and patterning strategies of liquid metal are presented. We review the latest progress in the design and fabrication of representative liquid metal fibers and their application in soft electronics such as conductors, sensors, and energy harvesting. Finally, we discuss the challenges of fiber-based soft electronics and provide an outlook on future prospects.

Correlated Study of Material Interaction Between Capillary Printed Eutectic Gallium Alloys and Gold Electrodes

Liquid metals (LMs) play a growing role in flexible electronics and connected applications. Here, LMs come into direct contact with metal electrodes thus allowing for corrosion and additional alloying, potentially compromising device stability. Nevertheless, comprehensive studies on the interfacial interaction of the materials are still sparse. Therefore, a correlated material interaction study of capillary-printed Galinstan (eutetic alloy of Ga/In/Sn) with gold surfaces and electrodes is conducted. Comprehensive application of optical microscopy, vertical scanning interferometry, scanning electron microscopy/spectroscopy, x-ray photon spectroscopy, and atomic force microscopy allow for an in depth characterization of the spreading process of LM lines on gold films, revealing the differential spread of the different LM components and the formation of intermetallic nanostructures on the surface of the surrounding gold film. A model for the growth process based on the penetration of LM along the gold film grain boundaries is proposed based on the obtained time-dependent characterization. The distribution of gold, Galinstan, and intermetallic phases in a gold wire dipped into LM is observed using X-ray nano tomography as a complementary view on the internal nanostructure. Finally, resistance measurements on LM lines connecting gold electrodes over time allow to estimate the influence on the material interaction on electronic applications.

Concept, hardware development, and clinical trials of a Galinstan based Mercury free sphygmomanometer: Merkfree

The aim of this work is to develop Merkfree-a mercury-free sphygmomanometer that looks, feels, and operates just like a traditional mercury sphygmomanometer (MS). For this we use Galinstan as a substitute for mercury, which is a non-toxic alloy of Gallium, Indium and Tin. Galinstan is nearly half as dense as mercury and sticks to class. To work with the lower density, we designed an enclosure and scale that is nearly double the length of MS. The issue of stickiness with glass was resolved by maintaining a small meniscus of a reducing agent in the measuring tube and tank of Merkfree. Clinical trials to validate the accuracy of Merkfree against MS and oscillometric sphygmomanometer (OS) were conducted over 252 patients. The results show a good correlation of the systolic and diastolic BP measurements from Merkfree with respect to MS and the OS. The mean absolute percentage error is less than 10% for both SBP and DBP. We also found that Merkfree has lower rounding-off errors compared to MS. Merkfree can be a viable alternative to mercury sphygmomanometer that can help achieve the goal of WHO in eliminating mercury from healthcare, while simultaneously making sure that gold standard technique of sphygmomanometry continues to be available to the clinicians.

Novel Biphasically and Reversibly Transparent Phase Change Material to Solve the Thermal Issues in Transparent Electronics

Highly integrated transparent electronic systems are experiencing significant thermal bottlenecks due to the rapid growth of transparent electronics and the lack of suitable transparent thermal management solutions. Therefore, transparent thermal management materials are highly desirable in modern transparent electronics. Based on the phase change properties of polyethylene glycol (PEG) and the encapsulable properties of epoxy resin (EP), we synthesize a biphasically and reversibly transparent PEG/EP composite for thermal energy storage (TPE-TES). Energy-driven structural rearrangements in cross-linked networks are responsible for the high transparency with practical thickness. According to SEM and TEM investigations, PEG and EP achieve submicron phase dispersion, while TPE-TES forms a smooth and continuous surface that suppresses diffuse reflections and contributes to improved visible light penetration. The unique combination of phase change and optical transparency gives TPE-TES the ability to regulate thermal storage, rapid temperature change, and spatial temperature uniformity of transparent electronics. Due to its flexibility, stability, and processability, TPE-TES is also suitable and ideal as thin surface coating films or thick transparent flexible substrates for a wide range of applications in the integration of electronic devices.

Electrocapillary Actuation of Liquid Metal in Microchannels

Controllable deformation of liquid metal by electrocapillary actuation (ECA) is empirically characterized in fluidic channels at the sub-millimeter-length scale. In 100-µm-deep channels of varying widths, the Galinstan liquid metal could move at velocities of more than 40 mm/s. The liquid metal could extend more than 2.5 mm into the channels at an electrocapillary actuation voltage of 3 V DC. The dynamic behavior of the liquid metal as it moves in the microchannels is described. These results are useful for designing microsystems that use liquid metal as a functional material.

Desktop-level small automatic guided vehicle driven by a liquid metal droplet

Gallium-based liquid metals (LMs) are a new type of intelligent material, and their ability to move under the action of an electric field provides new opportunities for the design of small flexible vehicles. However, due to the extremely high fluidity of LMs and the poor automatic control ability of LM vehicles, it's still a huge challenge to control the movement of LMs flexibly and accurately. Therefore, in this paper, a small traction vehicle is designed by putting the flexible LM in rigid armor to make the movement more controllable. Moreover, a desktop-level small automatic guided vehicle (sAGV) system is built by using an external control circuit to follow a predetermined trajectory. Firstly, the basic characteristics of the vehicles driven by a LM droplet are simulated and analyzed. Then the effects of different factors on the movement velocity of the vehicles are measured by experiment. Finally, as a preliminary application test, the sAGV system is used to control the vehicles following a specific trajectory and realize the targeted transportation of cargos. The sAGV system designed in this paper can realize the automatic and precise control of the movement of the small vehicle. The current findings will inspire the further construction of complex small operating systems and the realization of accurate control.

Supported Cu/W/Mo/Ni—Liquid Metal Catalyst with Core-Shell Structure for Photocatalytic Degradation

Room-temperature liquid metal is a very ideal material for the design of catalytic materials. At low temperatures, the liquid metal enters the liquid state. It provides an opportunity to utilize the liquid phase in the catalysis, which is far superior to the traditional solid-phase catalyst. Aiming at the low performance and narrow application scope of the existing single-phase liquid metal catalyst, this paper proposed a type of liquid metal/metal oxide core-shell composite multi-metal catalyst. The Ga2O3 core-shell heterostructure was formed by chemical modification of liquid metals with different nano metals Cu/W/Mo/Ni, and it was applied to photocatalytic degrading organic contaminated raw liquor. The effects of different metal species on the rate of catalytic degradation were explored. The selectivity and stability of the LM/MO core-shell composite catalytic material were clarified, and it was found that the Ni-LM catalyst could degrade methylene blue and Congo red by 92% and 79%, respectively. The catalytic mechanism and charge transfer mechanism were revealed by combining the optical band gap value. Finally, we provided a theoretical basis for the further development of liquid metal photocatalytic materials in the field of new energy environments.

3D Printable concentrated liquid metal composite with high thermal conductivity

Heat dissipation materials in which fillers are dispersed in a polymer matrix typically do not exhibit both high thermal conductivity (k) and processability due to a trade-off. In this paper, we fabricate heat dissipation composites which overcome the trade-off using liquid metal (LM). By exceeding the conventional filler limit, ten times higher k is achieved for a 90 vol% LM composite compared with k of 50 vol% LM composite. Further, an even higher k is achieved by introducing h-BN between the LM droplets, and the highest k in this study was 17.1 W m^-1 K^-1. The LM composite is processable at room temperature and used as inks for 3D printing. This combination of high k and processability not only allows heat dissipation materials to be processed on demand under ambient conditions but it also increases the surface area of the LM composite, which enables rapid heat dissipation.

Are Contact Angle Measurements Useful for Oxide-Coated Liquid Metals?

This work establishes that static contact angles for gallium-based liquid metals have no utility despite the continued and common use of such angles in the literature. In the presence of oxygen, these metals rapidly form a thin (∼1-3 nm) surface oxide "skin" that adheres to many surfaces and mechanically impedes its flow. This property is problematic for contact angle measurements, which presume the ability of liquids to flow freely to adopt shapes that minimize the interfacial energy. We show here that advancing angles for a metal are always high (>140°)-even on substrates to which it adheres-because the solid native oxide must rupture in tension to advance the contact line. The advancing angle for the metal depends subtly on the substrate surface chemistry but does not vary strongly with hydrophobicity of the substrate. During receding measurements, the metal droplet initially sags as the liquid withdraws from the "sac" formed by the skin and thus the contact area with the substrate initially increases despite its volumetric recession. The oxide pins at the perimeter of the deflated "sac" on all the surfaces are tested, except for certain rough surfaces. With additional withdrawal of the liquid metal, the pinned angle gets smaller until eventually the oxide "sac" collapses. Thus, static contact angles can be manipulated mechanically from 0° to >140° due to hysteresis and are therefore uninformative. We also provide recommendations and best practices for wetting experiments, which may find use in applications that use these alloys such as soft electronics, composites, and microfluidics.

Ga Based Particles, Alloys and Composites: Fabrication and Applications

Liquid metal (LM) materials, including pure gallium (Ga) LM, eutectic alloys and their composites with organic polymers and inorganic nanoparticles, are cutting-edge functional materials owing to their outstanding electrical conductivity, thermal conductivity, extraordinary mechanical compliance, deformability and excellent biocompatibility. The unique properties of LM-based materials at room temperatures can overcome the drawbacks of the conventional electronic devices, particularly high thermal, electrical conductivities and their fluidic property, which would open tremendous opportunities for the fundamental research and practical applications of stretchable and wearable electronic devices. Therefore, research interest has been increasingly devoted to the fabrication methodologies of LM nanoparticles and their functional composites. In this review, we intend to present an overview of the state-of-art protocols for the synthesis of Ga-based materials, to introduce their potential applications in the fields ranging from wearable electronics, energy storage batteries and energy harvesting devices to bio-applications, and to discuss challenges and opportunities in future studies.

Mapping between Surface Wettability, Droplets, and Their Impacting Behaviors

Droplet behaviors on solid surfaces will influence numerous droplet-based applications ranging from nonwetting-preferred water-repellent surfaces to wetting-preferred spray coatings. Understanding droplet behaviors is complicated and centered on integrating multiple parameters that include surface properties, droplet initial states, and other boundary conditions. Previous studies have observed that droplet impacting performance by showing their underlying mechanisms is sensitive to either droplet or surface boundary conditions. While the holistic view about droplet behaviors is still missing, here we study the droplet impacting and spreading behaviors by systemically varying surface conditions and droplet input parameters through the combination of optical experiments, simulations, and theoretical approaches. The observation defines three droplet behavior modes: bouncing, semibouncing, and spreading modes through their dynamic phases, where the most contributing parameters can be identified as the combination of initial Weber number and surface wettability. The We-θ phase diagram suggested here will provide a guideline for surface engineering with desired droplet dynamic behaviors.

Wide range continuously tunable and fast thermal switching based on compressible graphene composite foams

Thermal switches have gained intense interest recently for enabling dynamic thermal management of electronic devices and batteries that need to function at dramatically varied ambient or operating conditions. However, current approaches have limitations such as the lack of continuous tunability, low switching ratio, low speed, and not being scalable. Here, a continuously tunable, wide-range, and fast thermal switching approach is proposed and demonstrated using compressible graphene composite foams. Large (~8x) continuous tuning of the thermal resistance is achieved from the uncompressed to the fully compressed state. Environmental chamber experiments show that our variable thermal resistor can precisely stabilize the operating temperature of a heat generating device while the ambient temperature varies continuously by ~10 °C or the heat generation rate varies by a factor of 2.7. This thermal device is promising for dynamic control of operating temperatures in battery thermal management, space conditioning, vehicle thermal comfort, and thermal energy storage.

Current designs of thermal switches are limited by a lack of continuous tunability, low switching ratio, low speed, and not being scalable. Here the authors report a continuously tunable, wide-range, fast, and cost effective thermal switching approach that is demonstrated using compressible graphene composite foams.

Tunable Hydrodynamic Interfacial Instability by Controlling a Thermodynamic Parameter of Liquid-Liquid Phase Separation

Herein, we report on the hydrodynamic interfacial instability controlled by a thermodynamic parameter driving the liquid-liquid phase separation during fluid displacement in a Hele-Shaw cell. This instability remains even when the solution is guaranteed to be hydrodynamically stable. Adjusting the salt concentration helps control the miscibility of the solutions and change the pattern of the interface. We observe stable circular, fingering, and droplet formation patterns as the salt concentration is decreased from equilibrium. In addition, we analyze this interfacial instability using thermodynamic flux, which is determined from the growth rate of the interface, and provide a theoretical framework to quantitatively predict the transition points between the patterns. We find that the patterns transition to a state having higher entropy production.

High performance liquid metal thermal interface materials

Conventional thermal interface materials (TIMs) as widely used in thermal management area is inherently limited by their relatively low thermal conductivity. From an alternative, the newly emerging liquid metal based thermal interface materials (LM-TIMs) open a rather promising way, which can pronouncedly improve the thermal contact resistance and offers tremendous opportunities for making powerful thermal management materials. The LM-TIMs thus prepared exhibits superior thermal conductivity over many conventional TIMs which guarantees its significant application prospect. And the nanoparticles mediated or tuned liquid metal further enable ever conductive LM-TIMs which suggests the ultimate goal of thermal management. In this review, a systematic interpretation on the basic features of LM-TIMs was presented. Representative exploration and progress on LM-TIMs were summarized. Typical approaches toward nanotechnology enhanced high performance LM-TIMs were illustrated. The perspect of this new generation thermal management material were outlined. Some involved challenges were raised. This work is expected to provide a guide line for future research in this field.

Effect of static liquid Galinstan on common metals and non-metals at temperatures up to 200 °C

Liquid metal Galinstan (GaInSn) is corrosive in nature against other solid metals as its base component is gallium. This study experimentally investigated the compatibility of GaInSn with eight common metals at temperatures up to 200 °C for 2000 h, including aluminum, copper, brass, ferritic and austenitic stainless steels (E-brite, SS304L, SS316L), and nickel-chromium alloys (Inconel and Hastelloy). This assessment aims to assist in design and material selection of a liquid metal magnetohydrodynamics system that houses Galinstan for power generation by low temperature natural heat sources or industrial waste heat. Design and fabrication of this renewable power system required assurance of material compatibility with common construction and instrumentation materials. The most severe corrosion effects of GaInSn on the metal alloys were observed on aluminum, copper, and brass, which confirms the results of previously conducted studies. No obvious corrosion on stainless steel or nickel–chromium alloys were observed by this study, which reveals that stainless steel has a good resistance to attack by GaInSn up to 200 °C. Six non-metals were also evaluated, including acronitrile butadiene styrene (ABS), acrylic, nitrile rubber (Buna N), nylon, polyvinyl chloride (PVC), and Teflon, which were deemed to be compatible with GaInSn up to the temperatures tested.

Attributes, Fabrication, and Applications of Gallium-Based Liquid Metal Particles

This work discusses the attributes, fabrication methods, and applications of gallium-based liquid metal particles. Gallium-based liquid metals combine metallic and fluidic properties at room temperature. Unlike mercury, which is toxic and has a finite vapor pressure, gallium possesses low toxicity and effectively zero vapor pressure at room temperature, which makes it amenable to many applications. A variety of fabrication methods produce liquid metal particles with variable sizes, ranging from nm to mm (which is the upper limit set by the capillary length). The liquid nature of gallium enables fabrication methods-such as microfluidics and sonication-that are not possible with solid materials. Gallium-based liquid metal particles possess several notable attributes, including a metal-metal oxide (liquid-solid) core-shell structure as well as the ability to self-heal, merge, and change shape. They also have unusual phase behavior that depends on the size of the particles. The particles have no known commercial applications, but they show promise for drug delivery, soft electronics, microfluidics, catalysis, batteries, energy harvesting, and composites. Existing challenges and future opportunities are discussed herein.

A Rubik's microfluidic cube

A Rubik's cube as a reconfigurable microfluidic system is presented in this work. Composed of physically interlocking microfluidic blocks, the microfluidic cube enables the on-site design and configuration of custom microfluidics by twisting the faces of the cube. The reconfiguration of the microfluidics could be done by solving an ordinary Rubik's cube with the help of Rubik's cube algorithms and computer programs. An O-ring-aided strategy is used to enable self-sealing and the automatic alignment of the microfluidic cube blocks. Owing to the interlocking mechanics of cube blocks, the proposed microfluidic cube exhibits good reconfigurability and robustness in versatile applications and proves to be a promising candidate for the rapid deployment of microfluidic systems in resource-limited settings.

Reconfigurable, Self-Sufficient Convective Heat Exchanger for Temperature Control of Microfluidic Systems

Here, we demonstrate a modular, reconfigurable, and self-sufficient convective heat exchanger for regulation of temperature in microfluidic systems. The heat exchanger consists of polymer tubes wrapped around a plastic pole and fully embedded in an elastomer block, which can be easily mounted onto the microfluidic structure. It is compatible with various microfluidic geometries and materials. Miniaturized, battery-powered piezoelectric pumps are utilized to drive the heat carrying liquid through the heat exchanger at desired flow rates and temperatures. Customized temperature profiles can be generated by changing the configuration of the heat exchanger with respect to the microfluidic structure. Tailored dynamic temperature profiles can be generated by changing the temperature of the heat carrying liquid in successive cycles. This feature is used to study the calcium signaling of endothelial cells under successive temperature cycles of 24 to 37 °C. The versatility, simplicity, and self-sufficiency of the heat exchanger makes it suitable for various microfluidic based cellular assays.

Surface Modification with Gallium Coating as Nonwetting Surfaces for Gallium-Based Liquid Metal Droplet Manipulation

We report gallium (Ga) coating as a simple approach to convert most common microfluidic substrates to nonwetting surfaces against surface-oxidized gallium-based liquid metal alloys. These alloys are readily oxidized in ambient air and adhere to almost all surfaces, which imposes significant challenges in mobilizing liquid metal droplets without leaving residue. Various flat substrates (e.g., PDMS, Si, SiO₂, SU-8, glass, and parylene-C coated PDMS) were coated with thin film (75-200 nm in thickness) of gallium by evaporation and the coated gallium formed nanoscale uneven and rough surface through Ostwald ripening with its surface covered with oxide shell. Static and dynamic contact angles of the gallium-coated surfaces were found to be greater than 160°, while dynamic contact angle measurements showed contact angle hysteresis in the range of 6.5-24.4°. Surface-oxidized gallium-based liquid metal alloy droplets were shown to bounce off and roll on the gallium-coated surfaces without leaving any residue which confirms the nonwettability of the gallium-coated flat surfaces. Scanning electron microscopy (SEM) and atomic force microscopy (AFM) showed the gallium-coated flat substrates consist of nanoscale hemispherical structures with average surface roughness of 33.8 nm. Pneumatic actuation of surface-oxidized liquid metal droplets in PDMS microfluidic channels coated with gallium was conducted to confirm the feasibility of utilizing gallium coating as an effective surface modification for surface-oxidized gallium-based liquid metal droplet manipulation.

Investigation of the surface of Ga⁻Sn⁻Zn eutectic alloy by the characterisation of oxide nanofilms obtained by the touch-printing method

Ga–Sn–Zn eutectic alloy is a non-toxic liquid metal alloy which could be used in a multitude of applications, including as a heat transfer agent, in gas sensing, and in medicine. Alloys containing gallium readily oxidise in air, forming a thin oxide layer that influences the properties of liquid metals and which has not been studied. In this study, the oxide layer formed on Ga–Sn–Zn alloy was transferred at room temperature onto three substrates—quartz, glass and silicon. The contact angle between the liquid alloy and different substrates was determined. The obtained thin oxide films were characterised using atomic force microscopy, X-ray photon spectroscopy, and optical and transmission electron microscopy. The contact angle does not influence the deposition of the layers. It was determined that it is possible to obtain nanometric oxide layers of a few micrometres in size. The chemical composition was determined by XPS and EDS independently, and showed that the oxide layer contains about 90 atom % of gallium with some additions of tin and zinc. The oxides obtained from the eutectic Ga–Sn–Zn liquid alloys appear to be nanocrystalline.

Droplet-Based Microfluidic Thermal Management Methods for High Performance Electronic Devices

Advanced thermal management methods have been the key issues for the rapid development of the electronic industry following Moore’s law. Droplet-based microfluidic cooling technologies are considered as promising solutions to conquer the major challenges of high heat flux removal and nonuniform temperature distribution in confined spaces for high performance electronic devices. In this paper, we review the state-of-the-art droplet-based microfluidic cooling methods in the literature, including the basic theory of electrocapillarity, cooling applications of continuous electrowetting (CEW), electrowetting (EW) and electrowetting-on-dielectric (EWOD), and jumping droplet microfluidic liquid handling methods. The droplet-based microfluidic cooling methods have shown an attractive capability of microscale liquid manipulation and a relatively high heat flux removal for hot spots. Recommendations are made for further research to develop advanced liquid coolant materials and the optimization of system operation parameters.

Electric Actuation of Liquid Metal Droplets in Acidified Aqueous Electrolyte

The electric actuation of room-temperature liquid metals, such as Galinstan (gallium-indium-tin), has largely been conducted in alkaline electrolyte. Addition of surface-active anions and a proper acidic pH are expected to influence the interfacial tension of the liquid metal due to a high surface charge density. Hence, it should be possible to actuate liquid metals in such acidic environments. To ascertain this, at first, the dependence of the interfacial tension of Galinstan in NaOH, acidified KI, and acidified NaCl electrolyte on the concentration of the surface-active anions OH^-, I^-, and Cl^-, respectively, were studied. Subsequently, a systematic study of the actuation of Galinstan in acidified KI electrolyte was executed and compared to actuation in alkaline medium. In the presence of HCl and acidified NaCl electrolyte, the interfacial tension of Galinstan is only marginally altered, while acidified KI solution reduced the interfacial tension of Galinstan significantly from 470.8 ± 1.4 (no KI) to 370.6 ± 4.1 mN/m (5 M KI) due to the high surface charge density of the electric double layer. Therefore, in acidified electrolyte in the presence of surface-active anions, the electrically actuated motion of LM can be realized. In particular, the actuation of Galinstan achieves a higher average and maximum speed at lower applied voltage and power consumption for acidified KI electrolyte. The formation of high surface charge density in acidified environments signifies a paradigm shift and opens up new possibilities to tune interfacial tension and controlled LM droplet motion of room-temperature liquid metals.

Coloration of Liquid-Metal Soft Robots: From Silver-White to Iridescent

Gallium-based room-temperature liquid metals are becoming increasingly attractive and outstanding candidates for designing soft robots because of their remarkable electrical conductivity, superior flexibility, excellent stability, and low toxicity. However, the color of liquid metals is limited to shiny silver-white with high reflectivity, which is not helpful for camouflage, like that found in natural soft animals such as cephalopods. Herein, a biomimetic chromatic liquid-metal soft robot with tunable structural colors is reported. Colors ranging from white to gold and black appear on the surface of liquid metal when placed on a graphite substrate and mixed with Al foil in an electrolyte solution. A stable liquid-metal functional material with a rainbow-like appearance is realized under the regulation of an electric field. Further composition and structure characterization reveals that it is a nanoscale Ga₂O₃ film that displays the multicolor characteristic. The nanostructural film indicates that light scattering of Ga₂O₃ occurs when the liquid metal is on the graphite surface, and thin-film interference triggers iridescence when the liquid metals are subjected to electrolysis, respectively. These results provide a route to create kaleidoscopic and colorful liquid metals, which are expected to have diverse applications, especially in reinforcing soft robot design with intelligent camouflage function.

Materials and Structures toward Soft Electronics

Soft electronics are intensively studied as the integration of electronics with dynamic nonplanar surfaces has become necessary. Here, a discussion of the strategies in materials innovation and structural design to build soft electronic devices and systems is provided. For each strategy, the presentation focuses on the fundamental materials science and mechanics, and example device applications are highlighted where possible. Finally, perspectives on the key challenges and future directions of this field are presented.

Ga-Based Alloys in Microelectronic Interconnects: A Review

Gallium (Ga) and some of its alloys have a range of properties that make them an attractive option for microelectronic interconnects, including low melting point, non-toxicity, and the ability to wet without fluxing most materials-including oxides-found in microelectronics. Some of these properties result from their ability to form stable high melting temperature solid solutions and intermetallic compounds with other metals, such as copper, nickel, and aluminium. Ga and Ga-based alloys have already received significant attention in the scientific literature given their potential for use in the liquid state. Their potential for enabling the miniaturisation and deformability of microelectronic devices has also been demonstrated. The low process temperatures, made possible by their low melting points, produce significant energy savings. However, there are still some issues that need to be addressed before their potential can be fully realised. Characterising Ga and Ga-based alloys, and their reactions with materials commonly used in the microelectronic industry, are thus a priority for the electronics industry. This review provides a summary of research related to the applications and characterisation of Ga-based alloys. If the potential of Ga-based alloys for low temperature bonding in microelectronics manufacturing is to be realised, more work needs to be done on their interactions with the wide range of substrate materials now being used in electronic circuitry.

Liquid metals: fundamentals and applications in chemistry

Post-transition elements, together with zinc-group metals and their alloys belong to an emerging class of materials with fascinating characteristics originating from their simultaneous metallic and liquid natures. These metals and alloys are characterised by having low melting points (i.e. between room temperature and 300 °C), making their liquid state accessible to practical applications in various fields of physical chemistry and synthesis. These materials can offer extraordinary capabilities in the synthesis of new materials, catalysis and can also enable novel applications including microfluidics, flexible electronics and drug delivery. However, surprisingly liquid metals have been somewhat neglected by the wider research community. In this review, we provide a comprehensive overview of the fundamentals underlying liquid metal research, including liquid metal synthesis, surface functionalisation and liquid metal enabled chemistry. Furthermore, we discuss phenomena that warrant further investigations in relevant fields and outline how liquid metals can contribute to exciting future applications.

Simple, low-cost fabrication of semi-circular channel using the surface tension of solder paste and its application to microfluidic valves

This work presents a simple, low-cost method to fabricate semi-circular channels using solder paste, which can amalgamate the cooper surface to form a half-cylinder mold using the surface tension of Sn-Pd alloy (the main component in solder paste). This technique enables semi-circular channels to be manufactured with different dimensions. These semi-circular channels will then be integrated with a polymethylmethacrylate frame and machine screws to create miniaturized, portable microfluidic valves for sequential liquid delivery and particle synthesis. This approach avoids complicated fabrication processes and expensive facilities and thus has the potential to be a useful tool for lab-on-a-chip applications.

A Gallium-Based Magnetocaloric Liquid Metal Ferrofluid

We demonstrate a magnetocaloric ferrofluid based on a gadolinium saturated liquid metal matrix, using a gallium-based liquid metal alloy as the solvent and suspension medium. The material is liquid at room temperature, while exhibiting spontaneous magnetization and a large magnetocaloric effect. The magnetic properties were attributed to the formation of gadolinium nanoparticles suspended within the liquid gallium alloy, which acts as a reaction solvent during the nanoparticle synthesis. High nanoparticle weight fractions exceeding 2% could be suspended within the liquid metal matrix. The liquid metal ferrofluid shows promise for magnetocaloric cooling due to its high thermal conductivity and its liquid nature. Magnetic and thermoanalytic characterizations reveal that the developed material remains liquid within the temperature window required for domestic refrigeration purposes, which enables future fluidic magnetocaloric devices. Additionally, the observed formation of nanometer-sized metallic particles within the supersaturated liquid metal solution has general implications for chemical synthesis and provides a new synthetic pathway toward metallic nanoparticles based on highly reactive rare earth metals.

Customised spatiotemporal temperature gradients created by a liquid metal enabled vortex generator

Generating customised temperature gradients in miniaturised flow-free liquid chambers is challenging due to the dominance of diffusion. Inducing internal flows in the form of vortices is an effective strategy for overcoming the limitations of diffusion in such environments. Vortices can be produced by applying pressure, temperature and electric potential gradients via miniaturised actuators. However, the difficulties associated with the fabrication, integration, maintenance and operation of such actuators hinder their utility. Here, we utilise liquid metal enabled pumps to induce vortices inside a miniaturised liquid chamber. The configuration and rotational velocity of these vortices can be controlled by tuning the polarity and frequency of the energising electrical signal. This allows creation of customised spatial temperature gradients inside the chamber. The absence of conventional moving elements in the pumps facilitates the rapid reconfiguration of vortices. This enables quick transition from one temperature profile to another, and creates customised spatiotemporal temperature gradients. This allows temperature oscillation from 35 to 62 °C at the hot spot, and from 25 to 27 °C at the centre of the vortex within 15 seconds. Our liquid metal enabled vortex generator can be fabricated, integrated and operated easily, and offers opportunities for studying thermo-responsive materials and biological samples.

Soft Multifunctional Composites and Emulsions with Liquid Metals

Binary mixtures of liquid metal (LM) or low-melting-point alloy (LMPA) in an elastomeric or fluidic carrier medium can exhibit unique combinations of electrical, thermal, and mechanical properties. This emerging class of soft multifunctional composites have potential applications in wearable computing, bio-inspired robotics, and shape-programmable architectures. The dispersion phase can range from dilute droplets to connected networks that support electrical conductivity. In contrast to deterministically patterned LM microfluidics, LMPA- and LM-embedded elastomer (LMEE) composites are statistically homogenous and exhibit effective bulk properties. Eutectic Ga-In (EGaIn) and Ga-In-Sn (Galinstan) alloys are typically used due to their high conductivity, low viscosity, negligible nontoxicity, and ability to wet to nonmetallic materials. Because they are liquid-phase, these alloys can alter the electrical and thermal properties of the composite while preserving the mechanics of the surrounding medium. For composites with LMPA inclusions (e.g., Field's metal, Pb-based solder), mechanical rigidity can be actively tuned with external heating or electrical activation. This progress report, reviews recent experimental and theoretical studies of this emerging class of soft material architectures and identifies current technical challenges and opportunities for further advancement.

Fluid Flow and Mixing Induced by AC Continuous Electrowetting of Liquid Metal Droplet

In this work, we proposed a novel design of a microfluidic mixer utilizing the amplified Marangoni chaotic advection induced by alternating current (AC) continuous electrowetting of a metal droplet situated in electrolyte solution, due to the linear and quadratic voltage-dependence of flow velocity at small or large voltages, respectively. Unlike previous researchers exploiting the unidirectional surface stress with direct current (DC) bias at droplet/medium interface for pumping of electrolytes where the resulting flow rate is linearly proportional to the field intensity, dominance of another kind of dipolar flow pattern caused by local Marangoni stress at the drop surface in a sufficiently intense AC electric field is demonstrated by both theoretical analysis and experimental observation, which exhibits a quadratic growth trend as a function of the applied voltage. The dipolar shear stress merely appears at larger voltages and greatly enhances the mixing performance by inducing chaotic advection between the neighboring laminar flow. The mixer design developed herein, on the basis of amplified Marangoni chaotic advection around a liquid metal droplet at larger AC voltages, has great potential for chemical reaction and microelectromechanical systems (MEMS) actuator applications because of generating high-throughput and excellent mixing performance at the same time.

Liquid metal enabled microfluidics

Several gallium-based liquid metal alloys are liquid at room temperature. As 'liquid', such alloys have a low viscosity and a high surface tension while as 'metal', they have high thermal and electrical conductivities, similar to mercury. However, unlike mercury, these liquid metal alloys have low toxicity and a negligible vapor pressure, rendering them much safer. In comparison to mercury, the distinguishing feature of these alloys is the rapid formation of a self-limiting atomically thin layer of gallium oxide over their surface when exposed to oxygen. This oxide layer changes many physical and chemical properties of gallium alloys, including their interfacial and rheological properties, which can be employed and modulated for various applications in microfluidics. Injecting liquid metal into microfluidic structures has been extensively used to pattern and encapsulate highly deformable and reconfigurable electronic devices including electrodes, sensors, antennas, and interconnects. Likewise, the unique features of liquid metals have been employed for fabricating miniaturized microfluidic components including pumps, valves, heaters, and electrodes. In this review, we discuss liquid metal enabled microfluidic components, and highlight their desirable attributes including simple fabrication, facile integration, stretchability, reconfigurability, and low power consumption, with promising applications for highly integrated microfluidic systems.

Modeling of movement of liquid metal droplets driven by an electric field

We systematically investigate the factors during movement through experiment and innovative modeling, which combine pertinent forces.

Manipulation of Liquid Metals on a Graphite Surface

Liquid metals (LMs) in an alkaline electrolyte, when placed on a graphite surface, are able to be manipulated into desired flat, stable shapes with sharp angles, like triangles. Unique transformations and worm-like anti-gravity upslope LM locomotion under a low-voltage electric field are also revealed.

Self-contained microfluidic systems: a review

Microfluidic systems enable rapid diagnosis, screening and monitoring of diseases and health conditions using small amounts of biological samples and reagents. Despite these remarkable features, conventional microfluidic systems rely on bulky expensive external equipment, which hinders their utility as powerful analysis tools outside of research laboratories. 'Self-contained' microfluidic systems, which contain all necessary components to facilitate a complete assay, have been developed to address this limitation. In this review, we provide an in-depth overview of self-contained microfluidic systems. We categorise these systems based on their operating mechanisms into three major groups: passive, hand-powered and active. Several examples are provided to discuss the structure, capabilities and shortcomings of each group. In particular, we discuss the self-contained microfluidic systems enabled by active mechanisms, due to their unique capability for running multi-step and highly controllable diagnostic assays. Integration of self-contained microfluidic systems with the image acquisition and processing capabilities of smartphones, especially those equipped with accessory optical components, enables highly sensitive and quantitative assays, which are discussed. Finally, the future trends and possible solutions to expand the versatility of self-contained, stand-alone microfluidic platforms are outlined.