Enhancement of the rheological properties of magnetorheological foam via different constraint volumes foaming approach

The potential of magnetorheological (MR) foam, a recently developed porous smart material, has grown rapidly in recent years. The ability of MR foam to change its properties continuously, actively, and reversibly in response to a controlled external magnetic stimulus is one of its advantages for applications in advanced technology industries. However, its ability to store energy is still relatively low. This study attempts to address this drawback by highlighting a method to improve this ability by enhancing the material's storage modulus by introducing constrained foaming during the fabrication process. MR foam containing 75 wt% carbonyl iron particles (CIPs) was prepared in situ using two foaming approaches: free and constrained foaming. The effect of constraint foaming on the storage modulus enhancement was further investigated by reducing the mold length by 25 % and 50 %. The rheological properties of the fabricated MR foam samples were then examined using a rheometer in both the absence and presence of magnetic fields in an oscillatory shear mode. Thus, this study showed that constraint foaming has successfully improved the properties, especially regarding storage modulus and MR effect. When the mold volume was further reduced by 50 %, the storage modulus increased by about 50 % compared to a free-foaming MR foam at off-state conditions. Meanwhile, the results portrayed a higher storage modulus value under a 0.659 T magnetic field. This positive enhancement was believed to be due to a more compact CIP distribution. Hence, constraint volume MR foams were able to form stronger chain-like structures. The micrograph analysis by digital microscope revealed that the pore size decreased as the mold length was reduced. A shorter mold resulted in a more compact distribution of magnetic particles. As a result, MR foam with constrained foaming, especially at 50 % mold length, has a higher storage modulus. Overall, using constrained foaming to fabricate MR foam could improve the structure and mechanical properties of MR foam for a wide range of smart devices.