High magnetization composite magnetic fluid: structure, magnetorheology and new sealing mechanism in rotating seals

The sealing capacity of magnetofluidic (MF) rotating seals is limited by the highest magnetization of the sealing ferrofluids (FFs) of about 1000 G (80 kA m^-1). A sharp, almost an order of magnitude, increase in the supported pressure drop is possible by using a magnetorheological (MR) suspension as sealing fluid, owing to the much higher saturation magnetization of MR fluids compared to FFs. However, rotating seals with MR fluids have several shortcomings, such as a significant increase of the friction torque due to the growth of shear stress in the strong magnetic field specific to MF seals and leakage of the non-magnetic carrier liquid. At least partly, these issues can be avoided by using ferrofluid based extremely bidisperse MR suspensions of micrometer-sized iron (Fe) particles dispersed in a ferrofluid, as sealing fluid. The composite Fe₃O₄-Fe magnetic fluid used in this study consisted of hundreds of nanometers up to few microns size structures of interconnected (welded) Fe nanoparticles (FeMNPs) dispersed in a high colloidal stability ferrofluid with 500 G (40 kA m^-1) saturation magnetization. The volume fraction of iron NPs varies from 0.5 to 15% in the ferrofluid carrier which significantly increases the magnetization and simultaneously produces important changes of flow properties in magnetic field of the resulting composite fluid, from Newtonian to strongly non-Newtonian behavior. The evaluation of the magnetic and magnetorheological behavior includes the dependence of magnetization, effective viscosity, magnetoviscous effect and dynamic yield stress on the volume fraction of Fe nanoparticles dispersed in the ferrofluid carrier. The seal gap filled with interconnected Fe nanospheres consists in randomly distributed microregions with a high intensity and high gradient magnetic field that captures the ferrofluid and provides a new sealing mechanism. Already a small amount of interconnected Fe nanospheres additive (2.5-5.0% volume fraction) produces four times increase of the rotating seal burst pressure, a much higher increase than what can be obtained from using a conventional magnetic fluid with the same magnetization. The nano-composite sealing magnetic fluid proved to be a cost-effective solution to significantly increase the performance of multi-stage rotating MF seals.