Formation characteristics and acoustic regulation of liquid metal droplets in low-aspect-ratio channels

Abstract

The uniformity in size of liquid metal droplets is crucial in determining the accuracy of flexible circuit printing as well as the stability in signal transmission. In this study, the numerical simulation and the experiment method are combined to analyze the droplet preparation process of liquid metal. Furthermore, the mechanism of the surface acoustic wave as an external force dominating the breakup of the liquid metal interface is investigated. The results show that the squeezing pressure and the capillary force are the dominant forces of the interface evolution in the low-aspect-ratio (height/width) channel. When the dispersed phase flow rate is low, the interface will retract upstream of the channel under the influence of large interfacial tension after breakup, resulting in fluctuations in flow rate, and therefore, the stability of droplet size is weak. When the dispersed phase flow rate is high, the interface randomly breaks up under the influence of the Rayleigh–Plateau instability, which also leads to uneven droplet size. As the acoustic intensity increases, the acoustic radiation pressure gradually becomes the dominant force responsible for the squeezing and breakup of the interface. It increases the radial contraction rate of the interface, shortens the droplet generation period, and ultimately reduces the droplet size. Additionally, the size deviation value is significantly reduced from 10.13% to 1.05%. This study is useful in elucidating the evolution mechanism of liquid metal interfaces in low-aspect-ratio channels, improving the fundamental theory of interface breakup caused by acoustic radiation pressure, and providing theoretical guidance for the controlled and stable production of liquid metal droplets.