Dynamic and wear study of an extremely bidisperse magnetorheological fluid

In this work the friction and wear properties of five magnetorheological fluids (MRFs) with varying compositions are investigated. Considering that many of the proposed applications for these fluids involve lubricated contact between mobile metal-metal or polymer-metal parts, the relationship between MR response and wear behavior appears to be of fundamental importance. One of the fluids (MR#1) contains only the iron microparticles and base oil; the second and third ones (MR#2 and MR#3) contain an anti-wear additive as well. The fourth one (MR#4) is a well known commercial MRF. Finally, MR#5 is stabilized by dispersing the iron particles in a magnetite ferrofluid. The MR response of the latter fluid is better (higher yield stress and post-yield viscosity) than that of the others. More importantly, it remains (and even improves) after the wear test: the pressure applied in the four-ball apparatus produces a compaction of the magnetite layer around the iron microparticles. Additionally, the friction coefficient is larger, which seems paradoxical in principle, but can be explained by considering the stability of MR#5 in comparison to the other four MRs, which appear to undergo partial phase separation during the test. In fact, electron and optical microscope observations confirm a milder wear effect of MR#5, with almost complete absence of scars from the steel test spheres and homogeneous and shallow grooves on them. Comparatively, MR#2, MR#3 and, particularly, MR#1 produce a much more significant wear.