A Review on the Preparation Methods and Applications

of Magnetorheological (MR) Fluids

Arindam Das, PhD a, *, Shubham Ganar a, *, Atharva Navaratneb, *, Mayank Shreshthab, *,
Manik Sharmab, *, Saket Kohinkarb, *, Saurabh Kuradkarb, *, Svara Mehtab, *

a
Supervisor, b In alphabetical order
*
IIT Goa, Mechanical Engineering, Ponda, India, 403401

Abstract
Magnetorheological fluids (MRFs) are one of the categories of smart materials, whose viscosity
increases considerably in the presence of a magnetic field. These fluids are made by mixing stabilizer
additives with micron-sized magnetizable particles in a carrier fluid. The key characteristic of these
fluids is their capacity to switch quickly, within a few milliseconds of the application of a magnetic
field, from a liquid to a semi-solid state with adjustable yield stress. The most significant obstacles to
the widespread use of MRFs technology in contemporary businesses are their low magnetorheological
effect and instability. Researchers have suggested and applied a variety of techniques to enhance the
magnetorheological effect and the stability of these fluids. The primary goal of this work is to provide
an in-depth analysis of several techniques for preparing and stabilizing MR fluids. This paper also
briefly discusses the use of MR fluids and rheological models.

Keywords: MR Fluids, Preparation of MR Fluids, Rheology, Fluids

1. Introduction
Magnetorheological Fluids (customarily and in this work referred to as MR Fluids or MRFs)
are a type of smart material that change their viscosity and rheological properties under the influence
of an external magnetic field. These fluids consist of magnetic particles that are suspended in a non-
magnetic carrier fluid, and they exhibit unique and complex rheological behavior, such as shear thinning
and thickening, and yield stress behavior.

The development of MRFs has attracted significant research attention in recent years due to
their potential applications in a wide range of fields including automotive, aerospace, robotics, and
biomedical engineering.
MRFs have been used to develop advanced devices and systems such as dampers, brakes, and
clutches sensitive to vibration. MRF-based devices have shown significant improvements in
performance, efficiency, and precision compared to their conventional counterparts. Their rheological
properties enable them to quickly and precisely adjust their damping force in response to changes in
external vibration and shock, leading to improved safety and efficiency. MR clutches and brakes offer
several advantages over conventional friction-based systems, such as higher torque capacity, faster
response time, and longer service life. These devices find applications in industries, transportation,
machinery, and robotics.
One can also find applications of MRFs in development of prosthetic devices and rehabilitation
systems. MRF-based prosthetic devices, such as knee and ankle joints, can adjust their resistance and
damping force according to the user’s movement, leading to improved mobility, stability, and comfort.
MRF-based rehabilitation systems, such as robotic exoskeletons and haptic feedback systems, have
shown promising results in assisting the rehabilitation process of individuals with motor disabilities.
Furthermore, MR Fluids have opened up new avenues for research and development, leading
to the discovery of novel applications in various fields. For instance, MRF-based energy harvesting
systems have been developed to convert the waster vibration energy into useful electrical energy. MRF-
based soft robots have been developed to mimic the movement and behavior of living organisms,
leading to new possibilities in the field of robotics and artificial intelligence.
 The properties and behavior of MRFs have been studied extensively in the recent decade and
various models and simulations have been developed to better understand and quantify this behavior.
However, there remain some prominent research gaps as expressed in various published works.
Understanding the microstructure and behavior of MRFs under different magnetic fields and
shear rates is not well understood. While experimental results are widespread, an aptly modelled
explanation is not yet consolidated. Further, owing to lack of long-term stabilities of the prepared MRFs
including sedimentation and agglomeration, developing efficient and reliable manufacturing techniques
is also a research limitation at the moment. This has also hindered the wide availability and cost-
effectiveness of preparing and using MR Fluids.

This work presents an extensive literature review of the abovementioned aspects of MRFs and
based on published literature and experimental results.

2. Rheological Properties of MRFs

Magnetorheological effect is characterized by a reversible increase in the viscosity of a
magnetorheological fluid and showing yield stress due to the introduction of a magnetic field. This is a
result of a chain formation among the particles.
The MR effect can be controlled by varying the magnetic field intensity and rheological
characteristics of the MRF constituents. Controllable rheological characteristics of an MRF are due to
the induced polarity of suspended particles induced by the magnetic field [25]. In the presence of a
magnetic field, metal particles transform into a dipole and form a chain with adjacent particles which
can resist failure for certain shear rates. Interactions between these induced dipoles cause the particles
to be aligned along the applied field and form a columnar structure. The chain-like structure can inhibit
movement of the fluid and thus increase the viscosity of the suspension.
Mechanical energy needed to overcome this chain-like structure is increased by reinforcement
of the applied magnetic field [5]. When shear rate exceeds an extreme value, the chain structure will
break down and the fluid can flow. The stress which the MRF sustain at this high shear rate is called
apparent yield stress of the fluid [8].
Yield stress is the maximum stress which can be applied before the continuous flow. It is a
function of the magnetic field [25] and associated with the enhancement in viscoelastic behavior [11].
Yield stress as a crucial factor in industrial applications of MRFs in a specific range of magnetic field
[26]. In addition to the magnetic field intensity, this factor depends on shape, size distribution [26],
volume fraction of the particles, intensity of the applied magnetic field [8], and the various interactions
of the particles and formation of agglomerates [26].

To design MR devices and to predict how they work, one would need to find a specific relation
between shear stress and shear rate in the MRF [26]. Behavior of MRFs in the absence of a magnetic
field is very similar to the behavioral pattern of the carrier fluid, with very slight deviations [25].
One of the most fundamental equations to explain the behavior of magnetorheological fluids is
the Bingham model [26]. This model is extensively applied to explain flow curve (shear stress versus
shear rate) of MRFs. This model predicts that the apparent yield stress for each flow curve can be
extracted from interpolation at zero shear rate [26]. This model has been used in many previously
published literature [5,25].
Claracq et al., as reported in [26], have studied the rheological characteristics of
magnetorheological fluids and concluded that they follow Bingham plastic model very closely, with the
error being of a negligible order.
Another two-parameter equation is the Casson model [26]. Gabriel et al., as reported in [26],
observed that Casson model confirms the experimental results with a higher degree of accuracy and is
thus a more appropriate model for designing magnetorheological devices. One reason for this
observation is that unlike Bingham model, slope of shear stress versus shear rate in Casson model is a
function of the shear rate. Consequently, it is more consistent with the experimental results.
The Herschel-Bulkley model is a three-parameter model which was developed to describe flow
curve and yield stress of visco-plastic fluids and is more general in comparison to previous models [26].
It has been endorsed with the emphasis on a better consistency of this model with the behavior of a
broader range of MR fluids [26]. Other models, including the power law model, have been proposed to
explain the behavior of non-Newtonian fluids which are not extensively applied for magnetorheological
fluids [26].

3. Magnetorheological Fluid Applications

Potential applications of MRFs are in devices which need quick, continuous and reversible
change in rheological characteristics [5]. Magnetorheological devices have gained a great interest
during the last decades.
The ability to continuously determine the mechanical properties of the equipment is made
possible by a magnetorheological fluid, which brings mechanical devices into direct touch with an
electrical system. Modern dampers, clutches, and brakes are a few of these devices that use
magnetorheological fluids. The most common of these are magnetorheological dampers, which are
particularly useful as shock absorbers [26]. Among them are applications for control valves, power
steering pumps, artificial joints, engine mounts, alternators, sound propagation, chemical sensors, and
others [11].
Drug delivery and cancer treatment methods in medicine are some advanced applications of
magnetic suspensions [26]. Bica et al. [23] studied the potential applications of magnetorheological
suspensions. They identified important factors affecting the performance of MRFs in any specific
function. In another study, Wang et al. [24] evaluated various characteristics and applications of
magnetorheological fluids. According to their study, the three primary issues preventing the broad
deployment of MRF technology in many contemporary gadgets are their settling stability, cost
considerations, and durability.
Kciuk and Turczyn [1] studied basic properties of MRFs and their widespread applications in
various industries. Olabi et al. [25] studied characteristics of magnetorheological fluids as well as their
applications. According to their survey, promising aspects of MRF technology like fast response, simple
interface between electrical power input and mechanical power output and also precise controllability,
make them the next technology choice for many applications.

A damper is a tool used to lessen shock, as well as to restrict motion, balance kinetic force, etc.
A damper that incorporates magnetorheological fluids and is regulated by a magnetic field is known as
a magnetorheological damper. Since magnetorheological dampers may apply a variety of damping
forces to the suspension and are inherently fail-safe, they have been developed. The magnetorheological
damper can function as a passive damping system with known operating parameters whenever a
problem arises in the system, based on the magnetorheological fluid's specifications in the absence of a
magnetic field [26]. Applications for MR dampers include wind-induced vibration control in cable-
stayed bridges, prosthesis control, washing machines, seismic damage reduction in civil engineering,
and vibration control systems [1].

When the MRF flows through a valve, a magnetic field is applied to the fluid and causes
viscosity of the fluid to rise. This change in the viscosity creates resistance against flow of fluid through
the valve. The input pressure is increased and flow of the fluid slows down or completely stops.
Rosenfeld et al., as reported in [26], examined structure and performance of
magnetorheological and electrorheological valves and finally found that performance of the former
significantly depends on driving force and active volume of the fluid.

Another industrial use of magnetorheological fluids is optical polishing, which was initially
described by Kordonski et al. [9]. Abrasive particles carry out the polishing process when magnetic
particles create a chain-like structure in the presence of a magnetic field. The size of the magnetizable
particles has a considerable impact on the abrasive retention capacity and stiffness of a
magnetorheological fluid. Other factors that impact the quality of the workpiece surface include
concentration [26] and the kind of abrasive particles [24].

Magnetorheological brake is a device which is utilized for torque transmission. A rotational

magnetorheological brake in the presence of a magnetic field is able to change the braking torque
quickly [26]. The simple design and relative ease in controlling it makes MRF breaks a very cost-
effective choice for a wide variety of applications [26].

4. Preparation of MRFs
MR suspensions are prepared simply by mixing all the constituents together. The major
anomaly arises in the type and fraction of the components to be used.
An MRF usually has three main constituents: base fluid, magnetizable particles, and stabilizer
additives. The base fluid behaves like a carrier which contains the metal particles. This is the medium
in which the metal particles are suspended and can be assumed to be uniformly dispersed. Stabilizer
additives are added to overcome the sedimentation tendencies of the heavy magnetizable particles.
With the use of certain surfactants, such as stearic acid (to prevent irreversible aggregation),
iron particles are dispersed in silicone oil to create a straightforward and effective magnetorheological
fluid [12].
In order to efficiently create an MR fluid, one needs to disperse magnetizable particles into the
base fluid in an efficient way so particles do not aggregate and a homogenized suspension may be
attained. One way of avoiding aggregation is to add the stabilizers before adding the magnetizable
components in order to retain the uniform dispersion within the medium.

4.1 Continuous Phase

The base fluid primarily plays the role of a liquid in which magnetic particles of the dispersed
phase are suspended [26]. Viscosity of the base fluid is kept low in order to achieve the maximum MR
effect [25].
The base fluid can be a polar or a non-polar solvent, and is usually characterized by its
rheological properties and temperature stability. Some other factors which are considered include
compatibility with magnetic particles, chemical stability, surface tension, etc.
Some of the most commonly used carrier fluids in MRFs are petroleum-based oils, mineral oils,
silicon, polyester, polyether, water, and industrial hydro-carbonic oils. For any application, an
appropriate base fluid can be chosen based on the required properties, stability and magnetorheological
effect.
For instance, considering cost, environmental issues and cooling characteristics of the surface
which is to be cooled, water may be the idea choice for magnetorheological polishing processes [53].
Viscosity is one of the most important characteristics of the continuous phase in MRFs. Another
important feature of the carrier fluid in magnetorheological fluids is its low vapor pressure, so it is not
easily vaporized and can be used over a fairly wide range of temperatures.
An appropriate magnetorheological fluid should contain a carrier fluid with low viscosity and
should incorporate other essential characteristics for operational temperatures and redistribution of the
particles [5]. Determining the viscosity of the carrier fluid is essential, since low viscosity can lead to
instability and sedimentation problems, whereas a high viscosity may raise viscosity of the
magnetorheological fluid in the absence of a magnetic field which will cause abnormalities in the
experimental results. Generally, oils with low viscosity, like silicone oil, are preferred to make
magnetorheological fluids [8,26].

4.2 Dispersed Phase

Many metals, alloys and ceramics compositions can be used as particle phase to prepare a
magnetorheological fluid. Some of these particles are ferrite-polymers, iron–cobalt alloys, carbonyl
iron, nickel–zinc ferrites [26], iron and its compounds [25,26], and other magnetizable materials.
Among these particles, carbonyl iron and its alloys have the highest saturation magnetization [22].
These particles are magnetically of a varied domain and demonstrate a low magnetic coercivity
(magnetically soft materials) [9].
Soft materials are temporary magnets, a feature which is very important for reversibility of
magnetorheological effect. Since soft magnetic materials are easily magnetized and demagnetized, it is
possible to reversibly modify the rheological properties of MRF by applying an external magnetic field
[26]. Due to their availability and nontoxicity, Fe3O4 magnetic particles were frequently used in the
past to create magnetorheological solutions. Due to their low magnetic saturation, however, their
applicability has been restricted.
On the other hand, using ferrites (Fe3O4) in an MRF often involves issues related to
sedimentation and aggregation [26]. As mentioned before, the most common magnetic particle in MRF
preparation is high purity iron powder, known as carbonyl iron particles which is chosen because of its
high magnetic saturation and relevant particle size [9,22]. However, due to the high density of these
particles, sedimentation of these particles is still a major issue and has limited their widespread use in
commercial applications.
Therefore, numerous methods have been proposed to avoid the contact between carbonyl iron
particles and to reduce the density for slowing down their sedimentation.
Yield stress in MRFs containing carbonyl iron particles can be adequate for industrial
applications. An alloy of iron and cobalt is known to provide even higher saturation magnetizability
and is being increasingly used in MRF preparation, as reported in [5].
Gorodkin et al., as reported in [26], investigated rheological characteristics of an MRF
containing carbonyl iron particles. They observed that magnetizability of iron particles is linearly
proportional to the average size of the particles. Based on this observation, they concluded that the
magnetizability data can be used to evaluate the maximum permissible concentration of carbonyl iron
particles in magnetorheological fluids.
Park et al., as reported in [26], presented a review on studies of the stabilization of MR
suspension by using proper magnetizable particles. They focused on the use of CI and magnetite
particles and their composite as dispersed phase.
In Ashtiani et al.’s works [26], a magnetorheological fluid was prepared by using carbonyl iron
particles and a low viscosity lubricant oil. It was observed that yield stress is a function of weight percent
of the particles and magnetic field and increasing either of which will improve the yield stress
experimentally and numerically. Investigations using a rotational disk in rheological tests also yielded
similar results [17,61–65].
In another study, Kciuk et al. [26] have studied the characteristics of carbonyl iron-based
magnetorheological fluids. They used silica coating on carbonyl iron particles and silica additives to
prepare the MRF. Hua-jin et al. [26] prepared a magnetorheological fluid by dispersing gelatin carbonyl
iron composite in silicon oil. They showed that the MR effect is superior in lower magnetic field
intensities and the stability is very high in comparison with a bare carbonyl iron-based suspension.

The concentration of metal particles in an MRF can reach to 50 vol% [25]. Chiriac et al.
dispersed Fe microparticles in mineral oil to examine the impact of particle size and particle size
distribution. They discovered that the MR effect is enhanced when particle size or particle size
distribution are increased, and this augmentation is particularly pronounced in high magnetic field
strengths. The particles are sufficiently near and influenced by the flow field of neighboring particles
for high volume fractions of magnetizable particles. Additionally, hydrodynamic interactions are quite
important in the particle-laden flow. At 50 vol% of the particles, a rapid increase in viscosity is noticed
[22].
Lopez-Lopez et al., as reported in [26], investigated the MR effect of highly dense suspensions.
Their experimental result revealed that 50 vol% silica coated iron particles in mineral oil without further
additives is the upper limit of particles concentration in such an MRF.
Looking at the studies implemented in the context of magnetorheological fluids demonstrates
that carbonyl iron particles with average particle size of 4 μm are the most appropriate candidates for
the preparation of a magnetorheological fluid due to their great magnetic saturation characteristics and
relatively simple preparation process.
Depending on the needed stress range and the permitted range of sedimentation, the volume
proportion of these particles ranges from 10 to 70%. As was previously stated, considerable
consideration must be given to the choosing of magnetizable particles in order to create an effective and
stable MRF. For the MR effect to be reversible, particles' residual magnetism and coercivity must be
minimal. Magnetic saturation should be kept as high as possible for an audible MR effect. Size, shape,
and particle density are further determining factors. The optimal range for particle size is anticipated to
be 0.1–10 m. To prepare a stable MRF, low density particles are required. Along with determining the
type of particle, there are additional considerations including the compatibility of the particles with the
carrier fluid and their chemical stability.

4.3 Additives
In order to prevent gravitational sedimentation, create a stable suspension, improve the
lubricative characteristics, and alter the MRF's initial viscosity, several additives (stabilizers and
surfactants) are added to the magnetic suspension [1]. These substances include anti-friction and anti-
erosion chemicals, as well as suspending and thixotropic agents.
Grease and other thixotropic materials with a high viscosity are often added to
magnetorheological fluids to increase the stability of the particles against sedimentation.
To prevent the fluid from thickening after numerous uses, additives are also required to manage
the fluid's viscosity, particle sedimentation, and interparticle friction [25]. Thixotropic agents build a
network of particles that reduces sedimentation of the particles and results in a weak structure at low
shear rates [10].

5. Challenges in MRF Technology: Stability and the MR Effect

Operation in a wide range of temperature, chemical stability, stability against sedimentation,
reversible flocculation and high magnetic saturation are bottlenecks to the widespread use of MRFs.
Furthermore, an MRF must show high yield stress in the presence of a magnetic field and low apparent
viscosity in the absence of a magnetic field [11]. One of the major challenges in manufacturing a
magnetorheological fluid is to prevent sedimentation and aggregation of the particles. Sedimentation
which occurs due to a density and concentration gradient between magnetic particles and the carrier
fluid, restricts widespread applications of MRFs.

5.1 Stabilization
Sedimentation and low MR effect are the two key challenges in magneto-rheology. Methods to
improve stability and the MR effect include coating magnetizable particles, using nanowires, combining
magnetorheological fluids and ferrofluids, using stabilizer additives, using gels or other polymeric
liquids as the base fluid. A flowchart presented below indicates the possible methods. A brief overview
of some of the processes follows. The detailed review of these can be found in [26].

Stabilization
Techniques

Nano-Spherical Varying the Varying the Nano-Wire Increasing

Particle Coating
Particles Carrier Fluid Additive Particles Media Porosity

Fig 1. A schematic representation of stabilization alternatives

5.2 Particle Coating

Many recent works on stability of MRFs have focused on using magnetic particles in the core–
shell structure in order to overcome the sedimentation problem in magnetic suspensions. Composite
particles with core–shell structure are widely-used materials which often have improved physical and
chemical characteristics. Coating magnetic particles with organic polymers is one of the most common
stabilization techniques of magnetorheological fluids. In this method, sedimentation is mitigated by
reducing density difference between magnetic particles and base fluid [26]. Fig. 2 shows a schematic
image of coating process. Among the materials reported in literature, PMMA is widely accepted due to
the fact that this material improves the MR effect without significant increase in the off-state viscosity.
On the whole, coating carbonyl iron with polymeric compounds seems to be promising both for
improving stability and having adequate MR effect.
 Fig 2. From L to R: A bare particle (a) is activated (b); particle coating takes place via monomer addition (c)
until a coating consolidates symmetrically in all directions (d). (Figure is originally reproduced by the authors of
this review, adapted from reference [26])

5.3 Spherical Nanoparticles

Properties of nanoparticles are controlled by two interrelated factors: size and surface
characteristics. When metallic particle size decreases to the nanometer length scale, the surface to
volume ratio increases [26]. Nanoparticles are added to the magnetorheological fluid as solid additives
in order to prevent sedimentation phenomenon which occurs due to density mismatch between magnetic
particles and the liquid carrier. A schematic image of the MR effect is represented in Fig. 5 with and
without adding nanoparticles. Surveys about using nanoparticles in MRFs shows that nanoparticles with
high magnetic saturation such as iron and magnetite are efficient particles for using in ferro-fluid MRFs.
[26]

Fig 3. B refers to the magnetic field intensity. Lower figure shows how the presence of spherical
nanoparticles affects the MRF inter-particle structure on turning on the magnetic field. (Figure is originally
reproduced by the authors of this review, adapted from reference [26])

5.4 Stabilization Treatment and Additives

In magnetorheological fluids, only those chemicals are utilized that impact the suspension's
structural stability against sedimentation. According to [26], Lim et al. created an MRF from carbonyl
iron particles. When they looked at how adding fumed silica particles affected the stabilization of the
magnetorheological fluid, they discovered that doing so in a precise proportion was quite effective at
preventing the sedimentation of carbonyl iron particles.
A double layer of magnetite nanoparticles coated with lauric acid and/or myristic acid results
in the formation of a magnetorheological fluid with the proper stability, according to Bica et al. [26],
who studied the impact of several surfactants on the stability of a water-based MRF.
Polymeric compounds have been emphasized by Viota et al. [26] as stabilizer additives. They
investigated the rheological behavior of a polyacrylic acid–stabilized aqueous solution containing
magnetite particles. (PAA). The magnetorheological effect and its stability are improved by utilizing
magnetizable nanoparticles and stabilizing additives such fumed silica in the synthesis of MRF, which
is one of the available ways.

Conclusions
In many sectors, the use of magnetorheological fluids with suitable controllability is crucial.
With the help of stabilizer additives and suspensions of magnetizable particles in a base fluid,
magnetorheological fluids can simulate the behavior of a semi-solid material in a magnetic field. In the
context of MRFs, achieving high yield stress and minimizing magnetizable particle sedimentation are
two significant issues.
The rheological characteristics of these fluids are significantly impacted by these issues, which
mostly depend on the kind, shape, size, and volume percentage of the magnetizable particles. The
selection of magnetizable particles is influenced by a number of variables, including compatibility with
the carrier fluid, stability considerations, the desired MR effect, and others. The most promising
particles for the dispersed phase in MRFs, meanwhile, are carbonyl iron microparticles.
One approach to reducing interactions between the particles and particle density is to coat the
magnetizable particles. A new structure of magnetorheological fluids produced by suspending
magnetizable microparticles in a ferrofluid is coupled with another stabilization technique that is one
of the most promising and boosts the magnetorheological effect. Bonds are formed between the particles
when nanoparticles and microparticles are combined in MRFs, increasing the yield stress as a result.
Additionally, the presence of nanoparticles in the base fluid makes it more viscous, which
decreases sedimentation. In addition, several research suggest that the carrier fluid plays a significant
part in magneto-rheology. The key effective factor in sedimentation and instability of these suspensions
is the density differential between the base fluid and metallic particles, which can be reduced by using
fluids with higher density. In the absence of a magnetic field, these fluids' viscosity unfortunately
increased, which is undesirable. However, because to its accessibility, affordability, low viscosity, and
other factors, silicon oil is still regarded as the top choice for preparing magnetorheological fluid.
utilizing the right chemicals to enhance MR impact and stability.

So far, materials that can provide these requirements have not been identified. Finding a
composition of suspensions which can be more stable and also more cost effective still remains a
challenge.

Acknowledgements
<Add something about Shubham sir and Arindam sir?>

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