Exploring Electrochemical Extrusion of Wires from Liquid Metals

Liquid Metal Interface for Two-Precursor Autogenous Deposition of Metal Telluride-Tellurium Networks

Liquid metal-electrolyte can offer electrochemically reducing interfaces for the self-deposition of low-dimensional nanomaterials. We show that implementing such interfaces from multiprecursors is a promising pathway for achieving nanostructured films with combinatory properties and functionalities. Here, we explored the liquid metal-driven interfacial growth of metal tellurides using eutectic gallium-indium (EGaIn) as the liquid metal and the cation pairs Ag+-HTeO2+ and Cu2+-HTeO2+ as the precursors. At the EGaIn-electrolyte interface, the precursors were reduced and self-deposited autogenously to form interconnected nanoparticle networks. The deposited materials consisted of metal telluride and tellurium with their relative abundance depending on the metal ion type (Ag+ and Cu2+) and the metal-to-tellurium ion ratios. When used as electrode modifiers, the synthesized materials increased the electroactive surface area of unmodified electrodes by over 10 times and demonstrated remarkable activity for model electrochemical reactions, including HexRu(III) responses and dopamine sensing. Our work reveals the promising potential of the liquid metal-templated deposition method for synthesizing complex material systems for electrochemical applications.

Coating of gallium-based liquid metal particles with molybdenum oxide and oxysulfide for electronic band structure modulation

Liquid metal (LM) droplets are now used in many applications including catalysis, sensing, and flexible electronics. Consequently, the introduction of methods for on-demand alternating electronic properties of LMs is necessary. The active surface of LMs provides a unique environment for spontaneous chemical reactions that enable the formation of thin layers of functional materials for such modulations. Here, we showed the deposition of n-type MoO_x and MoO_xS_y semiconductors on the surface of EGaIn LM droplets under mechanical agitation to successfully modulate their electronic structures. The "liquid solution"-"liquid metal" interaction resulted in the formation of oxide and oxysulfide layers on the surface of LM droplets. The comprehensive study of electronic and optical properties revealed a decrease in the band gap of the droplets after surface decoration with MoO_x and MoO_xS_y, leading to deeper n-type doping of the materials. This method provides a facile procedure for engineering the electronic band structure of LM-based composites when they are necessary for various applications.

Imbibition-induced selective wetting of liquid metal

Herein, we present the imbibition-induced, spontaneous, and selective wetting characteristics of gallium-based liquid metal alloys on a metallized surface with micro-scale topographical features. Gallium-based liquid metal alloys are fascinating materials that have enormous surface tension; therefore, they are difficult to pattern into films. The complete wetting of eutectic alloy of gallium and indium is realized on microstructured copper surfaces in the presence of HCl vapor, which removes the native oxide from the liquid metal alloy. This wetting is numerically explained based on the Wenzel’s model and imbibition process, revealing that the dimensions of the microstructures are critical for effective imbibition-driven wetting of the liquid metal. Further, we demonstrate that the spontaneous wetting of the liquid metal can be directed selectively along the microstructured region on the metallic surface to create patterns. This simple process enables the uniform coating and patterning of the liquid metal over large areas without an external force or complex processing. We demonstrate that the liquid metal-patterned substrates maintain electrical connection even in a stretched state and after repetitive stretching cycles.

Liquid metals that have enormous surface tension are difficult to pattern into films. Here, authors report the spontaneous and selective wetting of a gallium-based liquid metal, which is induced by imbibition on a micro-structured metallized substrate.

Electrically Induced Liquid Metal Droplet Bouncing

Liquid metals, including eutectic gallium-indium (EGaIn), have been explored for various planar droplet operations, including droplet splitting and merging, promoting their use in emerging areas such as flexible electronics and soft robotics. However, three-dimensional (3D) droplet operations, including droplet bouncing, have mostly been limited to nonmetallic liquids or aqueous solutions. This is the first study of liquid metal droplet bouncing using continuous AC electrowetting through an analytical model, computational fluid dynamics simulation, and empirical validation to the best of our knowledge. We achieved liquid metal droplet bouncing with a height greater than 5 mm with an actuation voltage of less than 10 V and a frequency of less than 5 Hz. We compared the bouncing trajectories of the liquid metal droplet for different actuation parameters. We found that the jumping height of the droplet increases as the frequency of the applied AC voltage decreases and its amplitude increases until the onset of instability. Furthermore, we model the attenuation dynamics of consecutive bouncing cycles of the underdamped droplet bouncing system. This study embarks on controlling liquid metal droplet bouncing electrically, thereby opening a plethora of new opportunities utilizing 3D liquid metal droplet operations for numerous applications such as energy harvesting, heat transfer, and radio frequency (RF) switching.

Interfacial Electrochemical Polymerization for Spinning Liquid Metals into Core-Shell Wires

Metal wires are of great significance in applications such as three-dimensional (3D) printing, soft electronics, optics, and metamaterials. Ga-based liquid metals (e.g., EGaIn), though uniquely combining metallic conductivity, fluidity, and biocompatibility, remain challenging to be spun due to their low viscosity, high surface tension, and Rayleigh-Plateau instability. In this work, we showed that EGaIn as a working electrode could induce the oxidization of EGaIn and interfacial electrochemical polymerization of electroactive monomers (e.g., acrylic acid, dopamine, and pyrrole), thus spinning itself from an opening of a blunt needle. During the spinning process, the high surface tension of EGaIn was reduced by electrowetting and electrocapillarity and stabilized by polymer shells (tunable thickness of ∼0.6-30 μm on wires with a diameter of 90-300 μm), which were chelated with metal ions. The polymeric shells offered EGaIn wires with an enhanced endurance to mechanical force and acidity. By further encapsulating into elastomers through a facile impregnation process, the resultant elastic EGaIn wires showed a combination of high stretchability (up to 800%) and metallic conductivity (1.5 × 10⁶ S m^-1). When serving as wearable sensors, they were capable of sensing facial expressions, body movements, voice recognition, and spatial pressure distributions with high sensitivity, good repeatability, and satisfactory durability. Machine-learning algorithms further assisted to detect gestures with high accuracy.

Noncontact rotation, levitation, and acceleration of flowing liquid metal wires

Streams of fluids, particulates, and other flowing media are difficult to control after they have left a nozzle. Here, we present the noncontact manipulation of a free-flowing stream of liquid metal. Such streams form by electrochemically lowering the interfacial tension. The electrochemical reactions make the streams into soft current–carrying conductors presenting minimal resistance to manipulation via the Lorentz force in the magnetic field. Meanwhile, the movement of the stream induces a secondary force arising from Lenz’s law that causes the manipulated streams to levitate in unique shapes. This work, which exploits these forces in a visually stunning manner, enables shaping of fluids in a noncontact manner.

This paper reports the noncontact manipulation of free-falling cylindrical streams of liquid metals into unique shapes, such as levitated loops and squares. Such cylindrical streams form in aqueous media by electrochemically lowering the interfacial tension. The electrochemical reactions require an electrical current that flows through the streams, making them susceptible to the Lorentz force. Consequently, varying the position and shape of a magnetic field relative to the stream controls these forces. Moreover, the movement of the metal stream relative to the magnetic field induces significant forces arising from Lenz’s law that cause the manipulated streams to levitate in unique shapes. The ability to control streams of liquid metals in a noncontact manner will enable strategies for shaping electronically conductive fluids for advanced manufacturing and dynamic electronic structures.

Stencil Printing of Liquid Metal upon Electrospun Nanofibers Enables High-Performance Flexible Electronics

Flexible electronics as an emerging technology has demonstrated potential for applications in various fields. With the advent of the Internet of Things era, countless flexible electronic systems need to be developed and deployed. However, materials and fabrication technologies are the key factors restricting the development and commercialization of flexible electronics. Here we report a simple, fast, and green flexible electronics preparation technology. The stencil printing method is adopted to pattern liquid metal on the thermoplastic polyurethane membrane prepared by electrospinning. Besides, with layer-by-layer assembly, flexible circuits, resistors, capacitors, inductors, and their composite devices can be prepared parametrically. Furthermore, these devices have good stretchability, air permeability, and stability, while they are multilayered and reconfigurable. As proof, this strategy is used to fabricate flexible displays, flexible sensors, and flexible filters. Finally, flexible electronic devices are also recycled and reconfigured.

Polydopamine Shell as a Ga3+ Reservoir for Triggering Gallium-Indium Phase Separation in Eutectic Gallium-Indium Nanoalloys

Low melting point eutectic systems, such as the eutectic gallium-indium (EGaIn) alloy, offer great potential in the domain of nanometallurgy; however, many of their interfacial behaviors remain to be explored. Here, a compositional change of EGaIn nanoalloys triggered by polydopamine (PDA) coating is demonstrated. Incorporating PDA on the surface of EGaIn nanoalloys renders core-shell nanostructures that accompany Ga-In phase separation within the nanoalloys. The PDA shell keeps depleting the Ga³⁺ from the EGaIn nanoalloys when the synthesis proceeds, leading to a Ga³⁺-coordinated PDA coating and a smaller nanoalloy. During this process, the eutectic nanoalloys turn into non-eutectic systems that ultimately result in the solidification of In when Ga is fully depleted. The reaction of Ga³⁺-coordinated PDA-coated nanoalloys with nitrogen dioxide gas is presented as an example for demonstrating the functionality of such hybrid composites. The concept of phase-separating systems, with polymeric reservoirs, may lead to tailored materials and can be explored on a variety of post-transition metals.

Nanotip Formation from Liquid Metals for Soft Electronic Junctions

Liquid metals and alloys with high-aspect-ratio nanodimensional features are highly sought-after for emerging electronic applications. However, high surface tension, water-like fluidity, and the existence of self-limiting oxides confer specific peculiarities to their characteristics. Here, we introduce a high accuracy nanometric three-dimensional pulling and stretching method to fabricate liquid-metal-based nanotips from room- or near-room-temperature gallium-based alloys. The pulling rate and step size were controlled with a resolution of up to 10 nm and yielded different nanotip morphologies and lengths as a function of the base liquid metal alloy composition and the pulling parameters. The obtained nanotips presented high aspect ratios over lengths of a few microns and apexes between 10 and 100 nm. The liquid metal alloys were found confined within nanotips with about 10 nm apexes when vertically pulled at 100 nm/s. An amorphous gallium oxide skin was shown to cover the surface of the nanotips, while the liquid core was composed of the initial liquid metal alloys. The electrical contact established at the nanotips was characterized under dynamic conditions. The liquid metal nanotips showed an Ohmic resistance when a continuous liquid metal channel was formed, and a controllable semiconductor state corresponding to a heterojunction formed at the junction between the liquid metal phase and the gallium oxide semiconductor skin. The variable threshold voltages of the heterojunction were controlled via stretching of the nanotips with a 10 nm step resolution. The liquid metal nanotips were also used for establishing soft electronic junctions. This novel method of liquid metal nanotip fabrication with Ohmic and semiconducting behaviors will lead to exciting avenues for developing electronic and sensing devices.

Method to Reduce the Contact Resistivity between Galinstan and a Copper Electrode for Electrical Connection in Flexible Devices

This study demonstrates a method to mount electronic components using gallium-based liquid metals (LMs) with reduced contact resistivity between the LM and a copper (Cu) electrode. Gallium-based LMs have low volume resistivity and low melting points, and they are used as electronic components such as interconnects and sensors of stretchable electronic devices. However, the high contact resistivity of the oxide layer on the surface of the Ga-based LMs becomes a problem when the Ga-based LMs are used in contact with rigid electronic components. To overcome this problem, we studied herein the effect of the oxide layer on contact resistivity via the contact methods of the Ga-based LM (galinstan) and the Cu film. Through the placement of galinstan after the placement of the Cu film and application of vacuum to reduce the effect of the oxide layer, the contact resistivity was reduced to 0.59 × 10^-7 Ωm², which was 90% lower than that in the case where the Cu film was placed on galinstan on which the oxide layer grew (5.7 × 10^-7 Ωm²) (day 1). Additionally, it was found that the contact resistivity decreased in the same order (10^-8 Ωm²) over time regardless of the methods in which galinstan was applied (day 103). Furthermore, alloy formation on the Cu film surface was confirmed via elemental analysis. Finally, the mounting method using galinstan was demonstrated, which enabled the change in contact resistance to be maintained as low as 7.2% during 100% stretching deformation repeated 100 times (day 1 and day 130). Our results show that low and stable contact resistance with a high stretch tolerance can be achieved via the mounting method using galinstan based on our contact methods. This mounting method, therefore, expands the range of materials suitable for use as substrates and provides new opportunities for the development of stretchable electronics.

Bipolar Resistive Switching in Junctions of Gallium Oxide and p-type Silicon

In this work, native GaO_x is positioned between bulk gallium and degenerately doped p-type silicon (p⁺-Si) to form Ga/GaO_x/SiO_x/p⁺-Si junctions. These junctions show memristive behavior, exhibiting large current-voltage hysteresis. When cycled between -2.5 and 2.5 V, an abrupt insulator-metal transition is observed that is reversible when the polarity is reversed. The ON/OFF ratio between the high and low resistive states in these junctions can reach values on the order of 10⁸ and retain the ON and OFF resistive states for up to 10⁵ s with an endurance exceeding 100 cycles. The presence of a nanoscale layer of gallium oxide is critical to achieving reversible resistive switching by formation and dissolution of the gallium filament across the switching layer.

Metallophobic Coatings to Enable Shape Reconfigurable Liquid Metal Inside 3D Printed Plastics

Liquid metals adhere to most surfaces despite their high surface tension due to the presence of a native gallium oxide layer. The ability to change the shape of functional fluids within a three-dimensional (3D) printed part with respect to time is a type of four-dimensional printing, yet surface adhesion limits the ability to pump liquid metals in and out of cavities and channels without leaving residue. Rough surfaces prevent adhesion, but most methods to roughen surfaces are difficult or impossible to apply on the interior of parts. Here, we show that silica particles suspended in an appropriate solvent can be injected inside cavities to coat the walls. This technique creates a transparent, nanoscopically rough (10-100 nm scale) coating that prevents adhesion of liquid metals on various 3D printed plastics and commercial polymers. Liquid metals roll and even bounce off treated surfaces (the latter occurs even when dropped from heights as high as 70 cm). Moreover, the coating can be removed locally by laser ablation to create selective wetting regions for metal patterning on the exterior of plastics. To demonstrate the utility of the coating, liquid metals were dynamically actuated inside a 3D printed channel or chamber without pinning the oxide, thereby demonstrating electrical circuits that can be reconfigured repeatably.

Electrochemically Enabled Embedded Three-Dimensional Printing of Freestanding Gallium Wire-like Structures

The ability to pattern planar and freestanding 3D metallic architectures would enable numerous applications, including flexible electronics, displays, sensors, and antennas. Low melting point metals, such as gallium, have recently drawn considerable attention especially in the fields of flexible and stretchable electronics and devices owing to its unique properties, such as excellent electrical conductivity and fluidity. However, the large surface tension, low viscosity, and large density pose great challenges to 3D printing of freestanding gallium structures in a large scale, which hinder its further applications. In this article, we first propose an electrochemically enabled embedded 3D printing (3e-3DP) method for creating planar and freestanding gallium wire-like structures assisted with supporting hydrogel. After an enhanced solidification process and the removal of hydrogel, various freestanding 2D and 3D wire-like structures are realized. By simply reassembling the gallium structure into soft elastomer, a gallium-based flexible conductor and a 3D-spiral pressure sensor are demonstrated. Above all, this study presents a brand-new and economical way for the fabrication of 2D and 3D freestanding gallium structures, which has great prospects in wide applications in flexible and stretchable electronics and devices.

Stretchable, Stable, and Room-Temperature Gas Sensors Based on Self-Healing and Transparent Organohydrogels

Conductive hydrogels have emerged as promising candidate materials for fabricating wearable electronics because of their fascinating stimuli-responsive and mechanical properties. However, the inherent instability of hydrogels seriously limits their application scope. Herein, the stable, ultrastretchable (upon to 1330% strain), self-healing, and transparent organohydrogel was exploited as a novel gas-responsive material to fabricate NH₃ and NO₂ gas sensors for the first time with extraordinary performance. A facile solvent substitution method was employed to convert the unstable hydrogel into the organohydrogel with a remarkable moisture retention (avoid drying within a year), frost resistance (freezing point below -130 °C), and unimpaired mechanical and gas sensing properties. First-principles simulations were performed to uncover the mechanisms of antidrying and antifreezing effects of organohydrogels and the interactions between NH₃/NO₂ and organohydrogels, revealing the vital role of hydrogen bonds in enhancing the stability and the adsorption of NH₃/NO₂ on the organohydrogel. The organohydrogel gas sensor displayed high sensitivity, ultralow theoretical limit of detection (91.6 and 3.5 ppb for NH₃ and NO₂, respectively), reversibility, and fast recovery at room temperature. It exhibited the capabilities to work at a highly deformed state with nondegraded sensing performance and restore all the electrical, mechanical, and sensing properties after mechanical damage. The gas sensing mechanism was understood by considering the gas adsorption on functional groups, dissolution in the solvent, and the hindering effect on the transport of ions.

Highly Sensitive and Stretchable Strain Sensor Based on a Synergistic Hybrid Conductive Network

Highly sensitive and stretchable strain sensors have attracted considerable attention due to their promising applications in human motion detection, soft robot, wearable electronics, etc. However, there is still a trade-off between high sensitivity and high stretchability. Here, we reported a stretchable strain sensor by sandwiching reduced graphene oxide (RGO)-coated polystyrene microspheres (PS@RGO) and silver nanowires (AgNWs) conductive hybrids in an elastic polydimethylsiloxane (PDMS) matrix. Due to the synergistic effect of PS@RGO and AgNWs, the PDMS/PS@RGO/AgNWs/PDMS sensor exhibits a high initial electrical conductivity of 8791 S m^-1, wide working range of 0-230%, large gauge factor of 11 at 0-60% of strain and 47 at 100%-230% of strain with a high linear coefficient of 0.9594 and 0.9947, respectively, low limit of detection (LOD) of 1% of strain, and excellent long-term stability over 1000 stretching/releasing cycles under 50% strain. Furthermore, the strain sensor has been demonstrated in detecting human body motion and fan rotation with high stretchability and stability, showing potential application in intelligent robot and Internet of things.