Metal foams are highly sought-after porous structures for heterogeneous catalysis, which are fabricated by templating, injecting gas, or admixing blowing agents into a metallic melt at high temperatures. They also require additional catalytic material coating. Here, a low-melting-point liquid metal is devised for the single-step formation of catalytic foams in mild aqueous environments. A hybrid catalytic foam fabrication process is presented via simultaneous chemical foaming, melting, and sintering reaction of liquid metal nanoparticles. As a model, nanoparticles of tertiary low-melting-point eutectic alloy of indium, bismuth, and tin (Field's metal) are processed with sodium hydrogen carbonate, an environmentally benign blowing agent. The competing endothermic foaming and exothermic sintering reactions are triggered by an aqueous acidic bath. The overall foaming process occurs at a localized temperature above 200 °C, producing submicron-to micron-sized open-cell pore foams with conductive cores and semiconducting surface decorations. The catalytic properties of the metal foams are explored for a range of applications including photo-electrocatalysis, bacteria electrofiltration, and CO 2 electroconversion. In particular, the Field's metal-based foams show exceptional CO 2 electrochemical conversion performance at low applied voltages. The facile process presented here can be extended to other lowtemperature post transition and transition metal alloys.

Liquid metals are fast becoming a new class of universal and frictionless additives for the development of multifunctional soft and flexible materials. Herein, nanodroplets of eutectic gallium−indium alloy, which is liquid at room temperature, were used as a platform for the formulation of electrically conductive and magnetically responsive gels with the incorporation of Fe 3 O 4 nanoparticles. The nanoadditives were prepared in situ within a water-based solution of polyvinyl alcohol. A borax cross-linking reaction was then performed to yield multifunctional flexible and self-healing gels. The physicochemical properties and changes in the nanoadditives at each step of the gel preparation method were characterized. Oxidation and complexation reactions between the liquid metal and iron oxide nanoadditives were observed. A mixture of nanosized functional magnetic Fe 3 O 4 /Fe 2 O 3 and In−Fe oxide complexes was found to enable the magnetic susceptibility of the gels. The mechanical and self-healing properties of the gels were assessed, and finally, this flexible and multifunctional material was used as an electronic switch via remote magnetic actuation. The developed conductive and magnetic gels demonstrate great potential for the design of soft electronic systems.

Low melting point eutectic systems, such as the eutectic gallium–indium (EGaIn) alloy, offer great potential in the domain of nanometallurgy; however, many of their interfacial behaviors remain to be explored. Here, a compositional change of EGaIn nanoalloys triggered by polydopamine (PDA) coating is demonstrated. Incorporating PDA on the surface of EGaIn nanoalloys renders core–shell nanostructures that accompany Ga–In phase separation within the nanoalloys. The PDA shell keeps depleting the Ga3+ from the EGaIn nanoalloys when the synthesis proceeds, leading to a Ga3+-coordinated PDA coating and a smaller nanoalloy. During this process, the eutectic nanoalloys turn into non-eutectic systems that ultimately result in the solidification of In when Ga is fully depleted. The reaction of Ga3+-coordinated PDA-coated nanoalloys with nitrogen dioxide gas is presented as an example for demonstrating the functionality of such hybrid composites. The concept of phase-separating systems, with polymeric reservoirs, may lead to tailored materials and can be explored on a variety of post-transition metals.

Metallic foams, with intrinsic catalytic properties, are critical for heterogeneous catalysis reactions and reactor designs. Market ready catalytic foams are costly and made of multimaterial coatings with large sub-millimeter open cells providing insufficient active surface area. Here we use the principle of nanometallurgy within liquid metals to prepare nanostructured catalytic metal foams using a low-cost alloy of bismuth and tin with sub-micrometer open cells. The eutectic bismuth and tin liquid metal alloy was processed into nanoparticles and blown into a tin and bismuth nanophase separated heterostructure in aqueous media at room temperature and using an indium brazing agent. The CO2 electroconversion efficiency of the catalytic foam is presented with an impressive 82% conversion efficiency toward formates at high current density of −25 mA cm–2 (−1.2 V vs RHE). Nanometallurgical process applied to liquid metals will lead to exciting possibilities for expanding industrial and research accessibility of catalytic foams.

Liquid metal (LM) catalysts have been demonstrated to accelerate chemical reactions, providing an intriguing route to fine chemical synthesis with immense technological implications. Herein, we explore gallium-based LMs as catalysts to promote the oxidative self-polymerization of natural polyphenols, an emerging class of natural building blocks for surface functionalization with diverse biochemical properties. The oxidative polymerization of polyphenols, triggered by eutectic alloy of gallium and indium, results in nanocoatings with remarkably high reaction kinetics. The oxidative polymerization occurs in a wide pH range including an acidic environmenta condition previously unexplored for the deposition of phenolic coatings. The LM triggers the generation of highly active radical species from the oxidant causing the rapid oxidation of the polyphenols and their subsequent deposition on a range of different substrates. We further show that the LM-based catalytic system addresses several other limitations of existing coating methods including a narrow pH range, substrate specificity (precursor–dependent), and low coating uniformity. Finally, we demonstrate that the phenolic nanocoatings obtained from the acidic pH environment have excellent antioxidant and antibacterial properties without requiring any post-functionalization step. This process for creating phenolic nanocoatings may find applications in a wide range of industries, food science, and biomedicine.