A Brief Review of Surface Modification of Carbonyl Iron Powders (CIPs) for Magnetorheological Fluid Applications

Magnetorheological fluids (MRFs) is a smart fluid system that exhibits swift and reversible alterations in their rheological characteristics when exposed to an external magnetic field. MRFs are used for applications in various areas, including automotive systems, robotics, aerospace, and civil engineering. The performance of MRFs depends on the behavior of the dispersed magnetic particles, necessitating thoughtful consideration of particle traits to optimize fluid performance. Carbonyl Iron Powders (CIPs), high purity iron (>98%) reduced from penta carbonyl iron, are widely employed in MRFs due to their exceptional magnetic characteristics. Nevertheless, the innate surfaces of CIPs tend to conglomerate, leading to compromises in fluid stability and rheological performance. To overcome the challenges, an intensive research has been devoted to advancing surface modification techniques that augment the dispersion, stability, and overall functionality of MRFs based on CIPs. This review describes the comprehensive approach to surface modification of CIPs for highly stable MRFs. We discuss the various surface modification methodologies that have been explored to optimize the behavior of carbonyl iron-based MRFs. Coating techniques, surfactant functionalization, magnetic coatings, and emerging approaches such as nanocoatings and electrochemical modification are also summarized. Moreover, insights into potential applications and future prospects of these modified MRFs are provided.