Mechanical behaviours of solid–liquid composites filled with liquid metal droplets of precisely regulated dimensions

Abstract In this study, the solid–liquid phase transition and elevated surface tension of gallium-based liquid metal (LM) were employed to generate droplets with precisely controllable dimensions, thereby establishing a straightforward and practical methodological approach. Statistical analysis of the produced droplets indicated that their sizes conform to a Gaussian distribution characterized by a notably narrow standard error. The subsequent conversion of these LM droplets into solid powders facilitate their transfer and organization within an elastomer matrix, resulting in the solid–liquid composites with distinctive architectures. These composites were subjected to uniaxial tension to evaluate their mechanical properties across a spectrum of temperatures. A representative volume element that accurately reflects the actual microstructure of the composite was employed to numerically simulate the local stress and strain fields through finite element method modelling. The findings revealed that variations in the phase states of LM led to significant differences in deformation flexibility, damage progression, and failure mechanisms of the resulting composites. The uniformity in droplet size is expected to contribute to a more comprehensive understanding of the fundamental deformation mechanisms involved.