A review of challenges and solutions in the preparation and use of magnetorheological fluids

This review of MRF (magnetorheological fluids or MR fluids) brings out the challenges in methods of preparation, difficulties encountered in storage and use, and possible solutions to overcome the challenges. Magnetorheological fluid in the rheological fluid domain has found use due to its ability to change its shear strength based on the applied magnetic field. Magnetorheological fluids are composed of magnetizable micron-sized iron particles and a non-magnetizable base or carrier fluid along with additives to counter sedimentation and agglomeration. Magnetorheological fluids can respond to external stimuli by undergoing changes in physical properties thus enabling several improved modifications in the existing technology enhancing their application versatility and utility. Thus, magnetorheological fluid, a rheological material whose viscosity undergoes apparent changes on application of magnetic field, is considered as a smart material. Such materials can be used for active and semi-active control of engineering systems. Many studies on the designs of systems incorporating MR fluids, mainly for vibration control and also for other applications including brakes, clutches, dynamometers, aircraft landing gears, and helicopter lag dampers, have emerged over last couple of decades. However, the preparation as well as the maintenance of magnetorheological fluids involves several challenges. Sedimentation is a major challenge, even when stored for moderate periods of time. A comprehensive review is made on the problems confronted in the preparation of magnetorheological fluids as well as sustenance of the properties, for use, over a long period of time. Other problems encountered include agglomeration and in-use thickening (IUT) as well as rusting and crusting. Of interest is the mitigation of these problems so as to prepare fluids with satisfactory properties, and such solutions are reviewed here. The control of magnetorheological fluids and the applications of interest are also reviewed. The review covers additives for overcoming challenges in the preparation and use of magnetorheological fluids that include incrustation, sedimentation, agglomeration, and also oxidation of the particles. The methodology to prepare the fluid along with the process for adding selected additives was reviewed. The results showed an improvement in the reduction of sedimentation and other problems decreasing comparatively. A set of additives for addressing the specific challenges has been summarized. Experiments were carried out to establish the sedimentation rates for compositions with varying fractions of additives. The review also analyzes briefly the gaps in studies on MR fluids and covers present developments and future application areas such as haptic devices.