Magnetic fluid seals are well known for their zero-leakage performance but are limited at high rotational speeds due to heat generation and fluid loss. This study experimentally investigates the failure mechanisms of ester-based magnetic fluid seals at high speeds, specifically focusing on thermal dissipation and fluid loss. A custom-designed high-speed rotary seal test platform was developed, and experimental studies were conducted to evaluate sealing performance. Our results showed significant temperature increases and fluid loss at higher rotational speeds, with a noticeable fluid ejection phenomenon occurring at approximately 13.7 m/s, and the sealing gap temperature reached 92 °C at 9000 rpm under uncooled conditions. This study experimentally verified that the main failure mechanisms of magnetic fluid seals at high speeds are centrifugal force and thermal dissipation, and proposed future design directions. This research provides key insights into the failure of high-speed magnetic fluid seals and offers a potential approach for improved high-speed sealing performance.

Magnetic fluids, as smart nanomaterials, have been successfully used in sealing applications and other fields. However, the temperature of magnetic fluids in the sealing gap is a key factor affecting sealing performances, limiting their application in high-speed sealing fields. Since obtaining a direct measurement of the magnetic fluid’s temperature is difficult, due to the small clearance, accurately calculating the maximum temperature of the magnetic fluid layer in high-speed seals is crucial. Herein, a mathematical model for calculating the maximum temperature of the magnetic fluid layer was established, by using a reasonable simplification of high-speed sealing conditions, and the calculation formula was modified by studying the rheological properties of the diester-based magnetic fluid. The results suggest that the calculation of the maximum temperature is influenced by viscous dissipation, and both are related to the rheological characteristics of magnetic fluids. When the influence of rheological properties is ignored, the calculation results are not accurate for higher-velocity seals, but the calculation model applies to lower-velocity seals. When the influence of rheological properties is considered, the calculation results obtained by the corrected formula are more accurate, and they are applicable to both lower- and higher-velocity seals. This work can help us more accurately and conveniently estimate the maximum temperature of magnetic fluids in high-speed seal applications, which is of theoretical and practical research significance for determining sealing performances and thermal designs.

As one of the most mature applications of ferrofluid, the pole shoes of a ferrofluid seal are easily damaged under the situation of the large radial beating of the main shaft. Meanwhile, due to the small size, the pole teeth commonly used in pole shoes harbor problems such as poor processability and low seal pressure under a large gap. In order to solve the aforementioned problems, we proposed a new structure of the ferrofluid seal that uses a radial-charged ring magnet as the magnetic source. Then, considering that the ring magnets have problems of uneven magnetization and installation difficulties, we used split magnets to take the place of ring magnets and proposed the second new structure. According to the study on the distribution of magnetic field in seal gap axially and circumferentially, we obtained the simulation results of the two new structures’ seal pressure. The results revealed that the new structure of the ferrofluid seal with rectangular magnets can solve the aforementioned problems and exhibited a certain amount of sealing pressure.

Magnetic fluids, a new type of energy transfer fluid with tunable properties, have garnered significant interest from researchers worldwide. Hybrid magnetic fluids prepared by adding different types of nanoparticles exhibit superior thermophysical properties and functional characteristics. In this paper, we prepared a water-based magnetic fluid loaded with multi-walled carbon nanotubes (MCNTs), silver (Ag), and copper (Cu) to enhance thermal conductivity. Using a transient double hot-wire method, we designed and built an experimental measurement system for the thermal conductivity of magnetic fluids with an average measurement error of less than 5%. We studied the thermal conductivity of hybrid magnetic fluids under different conditions and evaluated the advantages and disadvantages of various models, including the Maxwell model, H&C model, Tim model, Y&C model, and Evans model. Our results show that MF+MCNTs, MF+Ag, and MF+Cu nanofluids can all improve the thermal conductivity of the carrier fluid, with MF+MCNTs exhibiting the best improvement effect of 10.93%. Among the five models evaluated, the Evans model had the best predictive effect with a deviation range within 5%. This work provides theoretical and practical reference for enhancing the thermal conductivity of magnetic fluids and provides a more accurate theoretical model for calculating the thermal conductivity of hybrid magnetic fluids.