Next-generation soft robots, wearable health monitoring devices, and human-machine interfaces require electronic systems that can maintain their performance under deformations. Thus, researchers have been developing materials and methods to enable high-performance soft electronic systems in diverse applications. While a variety of solutions have been presented, development of stretchable materials with a combination of high stretchability, electrical conductivity, cyclic stability, and manufacturability is still an open challenge. Throughout this dissertation, gallium-based<br>liquid metal alloy is used as the conductive material, leveraging its high conductivity and intrinsic stretchability for maintained performance under deformations. This dissertation presents both new liquid metal-based conductive materials and scalable manufacturing methods for the development of a diverse range of flexible and stretchable electronic circuits. First, a laser sintering method was developed to coalesce liquid metal micro/nanoparticles into soft, conductive structures enabled by oxide rupturing. The fast, non-contact, and maskless laser sintering technique, in combination with large-area spray-printing deposition, and high-throughput emulsion processing, provided a methodology to create different physical manifestations of liquid metal-based soft, stretchable, and reconfigurable electronics. Second, a liquid metal-based biphasic material was created using a thermal processing technique, yielding a printable, mechanically stable, and extremely stretchable conductor. This material’s compatibility with existing scalable manufacturing methods, robust interfaces with off-the-shelf electronic components, and electrical/mechanical cyclic stability enabled direct conversion of established circuit board assemblies to stretchable forms. The work presented in this dissertation paves the way for future mass-manufacturing of<br>soft, stretchable circuits for direct integration into smart garments or soft robots. <br>

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Liquid metals (LMs) are compelling candidates for use as plasma facing components (PFCs) in fusion devices to mitigate heat loading, limit damage due to erosion, and possibly breed tritium. When used as electrodes, such as in z-pinch devices, PFCs are subject to large current and magnetic flux densities resulting in large Lorentz forces. Furthermore, if the PFCs are LM, the forces excite wave behavior that has not previously been investigated. The work presented here first characterizes the response of LMs to current pulses which peak between 50 and 200 kA and generate magnetic pressures between 0.5 and 5 MPa. High-speed videography records the liquid metal free surface during and after the current pulse and captures a fast moving, annular jet of LM emerging from the main body. The vertical velocities of the jet range from 0.6 to 5.3 m/s which is consistent with hydrodynamic predictions. Ejection of small droplets is observed from the LM immediately after the current pulse, preceding the LM jet, with velocities ranging from −3.1 to 18.9 m/s in the vertical direction and −14.3 to 6.3 m/s in the radial. A statistical model is developed to predict the likelihood of certain LM PFC material contaminating a core plasma and the severity in such an event. Lastly, effectiveness of bulk wave movement mitigation is investigated with two solid barrier designs, a cylindrical and conical baffle. These designs were fabricated after an iterative design process with assistance from hydrodynamic simulations. A cylindrical baffle design is shown to be preferable for integration into future fusion devices for the reduced likelihood of interference with plasma column formation. / Doctor of Philosophy / Liquid metals are considered for use as a coating on the interior surfaces in nuclear fusion reactors because they can remove heat, reduce damage, and generate additional fuel for the reactor. There has been very little research on what happens to the liquid metal when large amounts of electric current pass through it, as would be necessary in some designs. The work presented here first shows the liquid responds to large amounts of electric current with a fast moving, ring-shaped jet that correlates to the specific amount of current used. A theoretical relationship is used to relate the jet to hydrodynamic scenarios with solid bodies entering liquids. Small droplets are also observed sprayed from the LM earlier in time and the likelihood and severity of liquid metal contaminating the fusion core is analyzed. Finally, solid barriers are used to slow down the jet and minimize the mass it contains. To reduce the likelihood that the jet interferes with the fusion core, certain characteristics of barriers are identified as being preferable for use in plasma devices.

"New, economical semi-solid metal (SSM) processes rely on forced convection during solidification to influence non-dendritic growth. The fundamental mechanisms that produce SSM microstructures in the presence of forced convection (due to fluid flow) are not fully understood. The objective of this work is to elucidate these mechanisms through the use of a new semi-solid slurry-making technique. Employing an apparatus developed at WPI, two alloy melts are mixed within a static reactor that induces convection and rapid cooling. Experiments carried out with this apparatus, named the “Continuous Rheoconversion Process” (CRP), result in globular semi-solid microstructures throughout a wide range of processing conditions. These conditions include the superheat in the melts before mixing, cooling rate of the slurry through the SSM range, and the presence or absence of inoculants in the melts. The results comprise repeatable sets of semi-solid microstructures having fine particle size and shape factors approaching unity. Even in the absence of melt inoculants, uniform distributions of α-Al particle sizes of about 60µm are attainable. Entrapped liquid is not present in the majority of the samples obtained with the CRP, and irregular particles that form in the process are of a limited distribution. Variation of slurry analysis methods indicates that these structures can be obtained consistently for both thixocasting and rheocasting applications. The design of the mixing reactor leads to turbulent fluid flow just as solidification commences. The results suggest that the following factors must be considered in identifying the mechanisms operating under the above conditions: copious nucleation of the primary phase; dispersion of nuclei throughout the bulk liquid; and inhibited remelting of nuclei due to temperature uniformity. In the CRP, these factors consistently lead to suppression of dendritic growth, significant grain refinement, and globular slurries. The exact fundamental mechanism leading to this effect is yet to be uncovered; however it is clear that temperature gradients ahead of the liquid are such that a cellular, non-dendritic morphology is the most stable growth form. Through further exploration of the process and identification of the operating mechanisms, future development of economical, continuous rheocasting methods will be facilitated."

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The solid, liquid, and solidification properties of Pd, Ag pure metals and especially PdxAg1-x alloys are studied by using the molecular dynamics simulation. The effects of temperature and concentration on the physical properties of Pdx$Ag1-x are analyzed. Sutton-Chen (SC) and Quantum Sutton-Chen (Q-SC) many-body potentials are used as interatomic interactions which enable one to investigate the thermodynamic, static, and dynamical properties of transition metals. The simulation results such as cohesive energy, density, elastic constants, bulk modulus, pair distribution functions, melting points and phonon dispersion curves obtained for Pd, Ag and PdxAg1-x are in good agreement with the available experimental data at various temperatures. The predicted melting points of Pd, Ag and their binary alloys by using Q-SC potential parameters are closer to experimental values than the ones predicted from SC potential parameters. The liquid properties such as diffusion constants and viscosities computed from Q-SC potentials are also in good agreement with the available experimental data and theoretical calculations. Diffusion coefficients and viscosity results calculated from simulation obey the Arrhenius equation well. The coefficients of the Arrhenius equation are given in order to calculate the self-diffusion coefficient and shear viscosity of Pd-Ag alloys at the desired temperature and concentration. Using different cooling rates, we investigate glass formation tendency and crystallization of Pd-Ag metal alloys, by analyzing pair distribution function, enthalpy, volume, and diffusion coefficient. Pd-Ag alloys show the glass structure at fast cooling rates while it crystallizes at slow cooling rates. Glass and crystallization temperatures are also obtained from the Wendt-Abraham parameter. The split of the second peak in the pair distribution function is associated with the glass transition. Glass forming ability increases with increasing concentration of Ag in Pd-Ag alloys. Thermal and mechanical properties of Cu, Au metals and their ordered intermetallic alloys Cu3 Au(L12), CuAu(L10), and CuAu3(L12) are also studied to investigate the effects of temperature and concentration on the physical properties of Cu-Au alloys. The simulation results such as cohesive energy, lattice parameter, density, elastic constants, bulk modulus, heat capacity, thermal expansion, melting points, and phonon dispersion curves are in good agreement with the available experimental and theoretical data at various temperatures. The Q-SC potential parameters are more reliable in determining physical properties of metals and their random and ordered alloys studied in this work

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The Sutton Chen and quantum Sutton Chen potentials are used in molecular dynamics simulations to describe the structural, thermodynamical, and transport properties of Pd, Ni and their binary alloys in solid, liquid, and glass phases. Static properties including elastic constants, pair distribution function, static structure factor, and dynamical properties consisting of phonon dispersion relation, diffusion coefficient, and viscosity are computed at various temperatures. The melting temperatures for Pd-Ni system are obtained. The transferability of the potentials is tested by simulating the solid and liquid states. The eutectic concentration Pd0.45Ni0.55 is quenched at four different cooling rates. The system goes into glass formation at fast cooling rates, while it evolves to crystal at slow cooling rate. Comparison of calculated structural and dynamical properties with the available experiments and other calculations shows satisfactory consistency.