Synthesis of sub-micrometer biphasic Au-AuGa₂/liquid metal frameworks

A novel biphasic sub-micrometer Au-AuGa₂/liquid metal framework, consisting of solid nanoparticles encapsulating liquid metal (LM) droplets, is introduced. By utilizing oxide-free galvanic replacement of a Ga-alloy LM with alkaline KAuBr₄, the controllable process of gold-based encapsulation of individual sub-micrometer LM droplets capped with polyvinylpyrrolidone, lysozyme or sodium alginate is demonstrated. The morphology, structure and composition of the encapsulated droplets are characterized in-depth via scanning electron microscopy, energy-dispersive X-ray spectroscopy, and X-ray diffraction. For the first time, the existence of two kinetic regimes leading to the controllable synthesis of either intermetallic AuGa₂ or Au nanoparticles to encapsulate LM droplets is highlighted via the study of the evolution of the pH of the reaction medium. The as-formed biphasic sub-micrometer Au-LM frameworks demonstrate moderate stability in an aqueous environment and formidable structural and chemical stability in ambient air at room temperature. The encapsulation process can be adapted to the micro-patterning of LM droplet surfaces to produce conductive Au-encapsulated LM droplets then sintered to recover LM lines, while the sub-micrometer Au-LM droplets can be reintegrated onto larger LM surfaces and volumes to create multi-metallic and multi-scale biphasic structures with controllable electrical properties. The adaptability of the encapsulation process to the macro-, micro- and nanoscale of liquid metal features with a wide range of surfactants could in principle allow its use in various systems and applications.