Application of liquid metal driven-abrasive flow to material removal for the inner surface of channel

• Published in: Powder technology 2025-02, Vol.452, p.120487, Article 120487
• Main Authors: Ma, Yapeng, Feng, Baoqi, Li, Kaixiang, Zhang, Lei
• Format: Article
• Language: English
• Subjects: Channel; Electric field; Liquid metal; Materil removal
• ISSN: 0032-5910
• DOI: 10.1016/j.powtec.2024.120487

Gallium-based eutectic liquid metal alloys possess unique properties such as deformability, high electrical conductivity, and low vapor pressure. These characteristics have generated significant interest in their application for stretchable electronics and microelectromechanical systems (MEMS). Precise manipulation of liquid metal within electrolytes is essential to meet specific functional requirements. This study investigates the electrostatic manipulation of liquid metal in an alkaline solution with abrasives for material removal from the inner surfaces of flow channels. The polarization of the double layer at the gallium‑indium alloy and electrolyte interface is analyzed, elucidating the principle of electrolyte propulsion via continuous electrowetting. A theoretical model is developed, and two- and three-dimensional transient and steady-state simulations of the liquid metal-driven abrasive flow are conducted. Results demonstrate that this method effectively removes material from the inner walls of straight channels during cyclic motion. Utilizing continuous electrowetting, an experimental apparatus was designed, where gallium‑indium liquid metal propelled silicon carbide abrasives against PMMA channel walls. Experimental results showed effective material removal, consistent with finite element simulations, confirming the feasibility of this innovative approach. Principle of liquid metal driven-abrasive flow machining (including liquid metal droplet, abrasive particles and Power supply) [Display omitted] •Innovative Liquid Metal-Driven Abrasive Flow: Proposed a novel abrasive flow method using gallium-based liquid metal for precise inner channel surface treatment.•Electric Field-Controlled Motion: Used electric fields to drive liquid metal and abrasive particles, enhancing energy and material removal efficiency.•Simulation and Validation: Conducted numerical simulations and experiments to analyze abrasive velocities and mass loss under varying voltages.•Improved Removal Efficiency: Experimental results confirmed significant surface roughness reduction, aligning with simulation predictions.•Future Research Directions: Explore optimization strategies, process parameters, and comparative studies with traditional polishing methods.