Preparation and Performance Evaluation of a High Temperature Stable Magnetorheological Fluid with Shear-Thinning Resistance

Magnetorheological fluid exhibits shear-thinning behavior when subjected to high temperature environments exceeding 100 °C, which will significantly compromise the operational stability and reliability of the associated mechanical systems. To enhance the performance of magnetorheological fluid, this study selects soft magnetic particles, base carrier fluid, and surfactants based on their resistance to high temperatures and shear-thinning effects. A novel magnetorheological fluid with enhanced thermal stability and shear stability is subsequently developed by carefully selecting flake-shaped carbonyl iron powder, dimethyl silicone oil, and surfactant exhibiting both sedimentation stability and high temperature resistance. The apparent rheological properties and mechanical performance of the fluid are systematically evaluated. Experimental results indicate that the sedimentation rate of the prepared magnetorheological fluid is 3.86% after standing for 10 days, the thermal expansion rate at 200 °C is 12.8%, and the evaporation rate following repeated high temperature applications is only 0.66%. The shear yield stress of the prepared magnetorheological fluid is 31.2 kPa under the magnetic field of 817 mT. The prepared magnetorheological fluid demonstrates excellent thermal stability and shear-thinning resistance, which holds significant potential for enhancing the performance of magnetorheological devices in future applications.