Modern nanomaterials coating processes feature high temperature environments and complex chemical reactions required for the precise synthesis of bespoke designs. Such flow processes are extremely complex and feature both heat and mass transfer in addition to viscous behaviour. Intelligent nano-coatings exploit magnetic nanoparticles and can be manipulated by external magnetic fields. Mathematical models provide an inexpensive insight into the inherent characteristics of such coating dynamics processes. Motivated by this, in the current work, a novel mathematical model is developed for dual catalytic reactive species diffusion in axisymmetric coating enrobing forced convection boundary layer flow from a linearly axially stretching horizontal cylinder immersed in a homogenous non-Darcy porous medium saturated withmagnetic nanofluid. Homogeneous and heterogeneous reactions, heat source (e.g. laser source) and non-linear radiative transfer are included. The Tiwari-Das nanoscale model is deployed. A Darcy-Forchheimerdrag force formulation is utilized to simulate both bulk porous drag and second order inertial drag of the porous medium fibres. The magnetic nanofluid is an aqueous electroconductive polymer comprising base fluid water and magnetic TiO2 nanoparticles. The TiO2 nanoparticles are one chemically reacting species (A) and a second species (B) is also present (e.g. oxygen) which also reacts chemically. Viscous heating and Ohmic dissipation are also included to produce a more physically realistic thermal analysis. The non-linear conservation equations proposed here with species diffusion (species A and B) are transformed via an appropriate stream function and scaling variables into a set of non-linear united multi-degree ODEs. The rising nonlinear ordinary differential boundary value problem is solved with four-point Gauss-Lobotto formulae in the MATLAB bvp5c routine. Validation is conducted with an Adams-Moulton predictor–corrector numerical scheme (AM2 coded in Unix). The widespread visualization of velocity, temperature, species A concentration, species B concentration, skin friction, local Nusselt number and species A and B local Sherwood numbers is included. For the higher Schmidt number the momentum diffusion rate exceeds the species diffusion rate and this will produce a depression in concentration values. Further, increasing Darcian parameter retards the local Nusselt number magnitudes since higher permeability corresponds to sparsity in the solid fibres, reduction in thermal conduction and a concomitant cooling of the cylinder surface.
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