This work focused on the development of a complete laboratory procedure for the rheological characterization of magnetorheological fluids (MRFs) by combining information gained from the literature and practical work performed in the laboratory. The procedure developed involves all the experimental stages for a comprehensive analysis, starting from the sample preparation, choice of the optimal measuring system, definition of the test, and rheometric parameters for the execution of an accurate and reliable analysis. Magnetorheology is a critical approach for studying the field-dependent properties of MRFs; however, measurement errors, often stemming from inappropriate rheometric test parameters, pose significant challenges. Additionally, sedimentation, caused by the large density mismatch between magnetic particles and the carrier fluid, presents a major obstacle that can compromise the analysis. Extensive work was performed for selecting the test parameters as well as defining the most relevant type of analysis to conduct with the defined procedure for the definition of the essential properties of an MRF for braking applications. This work is essential for the development of accurate card material for simulation tools, paving the way for broader utilization of MRFs in cutting-edge technologies.

The automotive market is looking for innovative braking solutions that can mitigate or eliminate secondary emissions. For this reason, new braking paradigms have been developed, and magnetorheological brakes could be considered a suitable solution due to their performance and controllability features. Reliability is a key factor for automotive braking systems, so it is essential to analyze the behavior of such technological solutions in iterative cycles to understand their capability of maintaining brake performance throughout their operative lifecycles. This article presents a preliminary experimental durability analysis and defines the testing standard procedures to be used as boundaries for this analysis. Then, a durability test bench is developed and produced to evaluate the magnetorheological fluid over an equivalent distance of 100,000 km. After the tests, the fluid’s characteristics are compared to its original features using a rheometer apparatus and Scanning Electron Microscopy (SEM).

This article focuses on modelling and validating a groundbreaking magnetorheological braking system. Addressing shortcomings in traditional automotive friction brake systems, including response delays, wear, and added mass from auxiliary components, the study employs a novel brake design combining mechanical and electrical elements for enhanced efficiency. Utilizing magnetorheological (MR) technology within a motor–brake system, the investigation explores the influence of external magnetic flux from the nearby motor on MR fluid movement, particularly under high-flux conditions. The evaluation of a high-magnetic-field mitigator is guided by simulated findings with the objective of resolving potential issues. An alternative method of resolving an interaction between an electric motor and a magnetorheological brake is presented. In addition, to test four configurations, multiple absorber materials are reviewed.