A study of the production and reversible stability of EGaIn liquid metal microspheres using flow focusing

This manuscript describes an experimental study of the production of micro-scale droplets of the room-temperature liquid alloy eutectic gallium indium (EGaIn) formed using a microfluidic flow-focusing device. The EGaIn surface oxidizes readily to form a passivating oxide "skin" that imparts some mechanical stability to the resulting microspheres, but does not appear to affect the dynamics of droplet formation. EGaIn has an interfacial tension nearly an order of magnitude larger than typical water-in-oil systems that are used to study droplet production in microfluidic flow-focusing devices. The size of the microdroplets increase as the ratio of the flow rates of the dispersed and continuous-phase increase for both EGaIn-in-glycerol and water-in-oil systems; however, these fluid pairs form droplets through different dispersing modes at otherwise identical flow conditions (i.e., flow rate ratios and capillary numbers). Consequently, the EGaIn droplets are larger than the water droplets. The difference in dispersing modes and droplet size are attributed to the relatively larger interfacial and inertial forces of the EGaIn system compared to the water-in-oil system. The addition of polyvinyl alcohol (PVA), which is known to bind to oxide surfaces, to the continuous phase yields stable, monodisperse emulsions of liquid metal. These emulsions can be destabilized on demand by changing the solution pH, allowing the liquid metal to be recovered. The ability of the PVA to bind to the liquid metal also influences droplet production by changing the shape of the liquid as it approaches the orifice of the flow focusing device, which results in droplets with smaller diameters relative to those formed without PVA.