The formulation and synthesis of magneto-rheological (MR) fluids formed by submerging iron particles in carrier fluids are the key points of this work. To reduce the corrosion, agglomeration, and sedimentation constraints of the MR fluid (MRF), iron particles are coated with natural gums like guar and xanthan. Various MR fluid samples were prepared using combinations of carrier fluids (paraffin oil and synthetic oil), magnetic particles (carbonyl iron and atomized iron dust), and additives. The magnetic particles were characterized using scanning electron microscopy (SEM). Carbonyl iron has a fiber-like structure, whereas atomized iron dust has a granular structure. The MR fluid containing xanthan gum-coated iron particles showed improved sedimentation properties. Furthermore, the magnetic field of the magnetic piston was tested by supplying power, and it was observed that the magnetic flux density increased with an increase in the current in amperes. By conducting a visual inspection, the sedimentation analysis of the prepared MR fluids demonstrated that MRF 2 and MRF 1 improved the sedimentation rate more significantly than the others. The rheological properties of the MR fluids were determined by measuring their yield stress with respect to the applied magnetic flux density. Paraffin oil-based MR fluid mixed with xanthan gum-coated carbonyl iron (MRF 2) showed higher yield stress than other fluids. The higher value of yield strength will boost the damping force of the MR damper to effectively suppress vibrations in the system.
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