Varying Volume Fractions Research Articles

A theoretical and experimental investigation of continuous oil–water gravity separation

In this study, we have developed a mathematical model for a three-phase separator. The model consists of two sections: the inlet section and the separation section, separated by a perforated calming baffle. In the inlet section, two dispersion layers undergo droplet size evolution due to turbulent breakage and coalescence, described by a spatially homogeneous PBE. In the separation section, the two dispersion layers flow alongside each other and interact at an interface. The volumetric flow and velocity profiles are influenced by interfacial coalescence, with considerations for plug and laminar flow assumptions. The model incorporates droplet gravity-driven transport using the Kumar and Hartland model, binary and interfacial coalescence employing a film drainage model, and an effective diffusion term to account for the formation of the dense packed layer which ensures a physical volume fraction range of 0–1. Steady-state and transient numerical solvers are developed to solve the resulting advection–diffusion equations. Additionally, a series of experiments were conducted using a lab-scale multi-parallel pipes separator to investigate the impact of varying volume fractions and flow rates on the separation efficiency of the equipment. The model results are compared with the experimental data which shows relatively good agreement.

Quantitative analysis of flame luminance and explosion pressure in liquefied petroleum gas explosion and inerting: Grey relation analysis and kinetic mechanisms

To evaluate the explosion intensity by flame luminance, a series of explosive and inerting tests on LPG in a 20-L spherical chamber were taken. A quantitative assessment of flame luminance was performed using the grey level theory, and the association between explosion pressure parameters and flame luminance parameters was examined through grey relation analysis. Furthermore, the intrinsic relationship and mechanism between these two variables were explored based on heat-chain reaction kinetics and energy conversion. The findings revealed a synchronous trend between flame luminance and explosion pressure during the LPG explosion process. Notably, a significant positive correlation between explosion pressure and flame luminance was established. Flame luminance emerged as a valuable indicator of explosion intensity, akin to explosion pressure. The grey relational grade between flame luminance and explosion pressure remained remarkably consistent under varying volume fractions of both LPG and CO2. The addition of CO2 exerted a comprehensive influence on factors such as reaction rate, heat release rate, and the concentration of key radicals. This collective impact resulted in reduced explosion pressure and flame luminance. This study offers a theoretical foundation for assessing explosion risks and enhancing energy safety management within the domains of chemical, petroleum, and natural gas industries.

Local strain heterogeneity and damage mechanisms in zirconia particle-reinforced TRIP steel MMCs: in situ tensile testing with digital image processing

In this work, the microstructural deformation and damage mechanisms of TRIP steel metal matrix composites (MMCs) reinforced with Magnesia Partially Stabilized Zirconia (Mg-PSZ) particles are investigated by employing in situ tensile testing within a scanning electron microscope chamber, complemented by digital image correlation and advanced image processing techniques. The study is carried out on samples with varied volume fractions (0%, 10%, and 20%) of zirconia particles and damage mechanisms in different samples under specified loading conditions. Through both qualitative and quantitative assessments of deformation, damage, and clustering, the investigation provides a comprehensive understanding of the distribution and damage initiation. The study findings reveal that, generally, the steel matrix exhibits high toughness, with minimal occurrences of microcracking at high strains that cause significant damage. In samples with increasing particle content, delamination at the matrix–particle interface and cracking of Mg-PSZ particles were found to be critical contributors to material failure and were quantitatively analyzed using computational analyses conducted with MATLAB. The work highlights the initiation and evolution of each damage mechanism in zirconia particle-reinforced TRIP steel MMCs to facilitate scientists and engineers in improving manufacturing and application decisions in industries such as automotive, aerospace, and heavy machinery, which demand materials with exceptional toughness and durability.Graphical

Performance assessment of a sample nanorefrigerant cooling process as a function of flow Reynolds number, evaporator and ambient temperatures

In this paper available experimental data of nanorefrigerant, NRF cooling process are processed using MATLAB to determine the coefficient of performance COP as a function of Reynolds number, Re of NRF, evaporator and ambient temperatures, Te and Ta as a novelty. The cooling process performance assessment of NRF is provided in comparison with a pure refrigerant, R through relative COP term, COPr. The used data ranges with 20–70 nm of Al2O3 in R134a are at varying volume fraction, φ of 0.075–0.303% and volumetric flow rate, Q of 6.5–11 L/h for Ta in 294–306 K and Te in 288–309 K. Re calculations are based on the thermophysical parameters evaluated at Te not only in the cited experimental ranges of Q, φ but also extrapolated for the extended range of Q of 15–25 L/h for a generalization purpose. Since data processing is under the interactive influence of the parameters the functional relationships of COP, Re, φ, Te are expressed as 3D graphical plots which are the start of a trial-error procedure. The experimental data are expressed in terms of fitted equations for functional relationships between various non-dimensional parameters as Re, COP, (COP*φ), (COP*Te/Ta*φ), (Re*Te/Ta*φ), (Re*Te/Ta), and COPr to provide a practical assistance for whom designing and using NRF cooling. A functional relationship of Re*(Te/Ta) with COPr at varying φ is found as the most critical output of the study due to the practice of the appeared parameters in cooling performance assessment. COPr>1 corresponds to φ>0.151% for the processed data ranges.

Investigation of ballistic performance on metal-coir fiber composite laminate with variation of fiber volume fraction: Experimental and simulation

Investigation of ballistic performance on metal-coir fiber composite laminate with variation of fiber volume fraction: Experimental and simulation

Study on the fatigue life and toughness of recycled aggregate concrete based on basalt fiber

This paper studies the influence of basalt fibers on the mechanical properties, fatigue life, and toughness of Mechanically Recycled Aggregate Concrete (MRAC). Basalt fibers of varying volume fractions and lengths, along with quantified amounts of mineral powder and fly ash, are incorporated into MRAC to prepare Basalt Fiber Mechanically Recycled Aggregate Concrete (BFMRAC). The results of basic mechanical tests and fatigue tests showed that mineral powder and fly ash reduce cement consumption, achieve the effect of green construction, and basalt fibers improve the mechanical properties and toughness of concrete. The results of the response surface method (RSM) model indicate that the volume fraction of basalt fibers has a greater influence on the mechanical properties of BFMRAC compared to fiber length. The fatigue test results indicate that under different fiber volume fractions and lengths, the uniaxial compressive fatigue life (N) of specimens for each mix proportion is consistently improved. When the length of basalt fibers is 12 mm and the volume fraction is 0.3 %, the uniaxial compressive fatigue life of BFMRAC reaches its maximum (231638), which is twice that of MRAC. When the survival rate (P) is set to 0.5, with a basalt fibers volume content of 0.3 % and a length of 12 mm, the fatigue limit strength (Se) attains its maximum (0.8648 fc). When stress levels (S) reach 0.75 and the basalt fibers length is 12 mm, the relative CI Intensifying Coefficient achieves its maximum (1.133), resulting in optimal fatigue toughness. When the basalt fibers length is 6–12 mm, Se generally increases with the increase of fiber length, and the enhancement effect is best at 12 mm.

Impact of Different Protrusions in Energy Transfer and Fluid Flow Characteristics Using Al₂O₃ Nanofluid in Pipe Flow

The study investigates how the protruded surface (the part sticking out of an otherwise flat surface) over the small channel affects flow characteristics and heat transfer within a circular flow regime, utilizing computational methods. This investigation uses an alumina nanofluid to compare and analyze the thermo-physical parameters of protruding pipes such as boxes, cylinders, dimples, and pyramids in pipe flow. Alumina nanofluid with varying volume fractions was evaluated as a thermo-fluid under laminar flow conditions, exploring its ability to enhance energy transmission (heat) over the protruded channels. The protruded surface induces turbulence around the protruded region, altering the coolant's physical characteristics. Since heat transfer predominantly occurs on surfaces, the alteration in surface geometry due to the protruded shape increases detectable heat transfer and the Nusselt number. With an increase in the volume percentage of nanofluids, there's a tendency for pressure loss to rise along the flow direction's centerline. The dimpled channel exhibits the highest Nusselt number among all protruding channels, indicating that increasing the Reynolds number also increases the surface heat transfer coefficient for all protrusions. When compared to the base fluid, cylindrical protrusions show the greatest pressure drop. Additionally, comparing a protruded channel with base fluid to one with a 4% volume of alumina nanofluid, it can be observed that the latter significantly improves heat transfer, followed by volume fractions of 1% to 3%.

Preparation and energy absorption of flexible polyurethane foam with hollow glass microsphere

This paper presents the preparation of a partially open-cell and partially closed-cell flexible polyurethane foam material (flex-PUF), which exhibits improved cushioning performance compared to conventional protective materials. Hollow Glass Microspheres (HGM) were used as a filling material to enhance the compressibility of the material. In order to investigate the effects of HGM on the multi-impact protection and vibration damping performance of flex-PUF with different thicknesses, flex-PUF samples filled with varying volume fractions of HGM were subjected to multi-impact testing and dynamic viscoelasticity experiments. The destructive mechanism of HGM under impact was observed using scanning electron microscopy (SEM). The experimental results revealed that, under the same impact energy conditions, filling flex-PUF with HGM reduced the maximum impact displacement while enhancing energy absorption, although at the expense of cushioning performance. As the number of impact increases, the stiffness of flex-PUF decreased. In the vibration experiments, as the frequency increased, the proportion of flex-PUF’s viscous damping energy dissipation decreases.

Assessment of flexural response of RC beams and unrestrained shrinkage of fiber-reinforced high-volume fly ash-based no-aggregate concrete and self-compacting concrete

The use of industrial byproducts as a substitute for cement in concrete production to improve its properties is becoming a widespread practice in producing sustainable concrete. Although research around the world emphasizes higher substitution levels of fly ash (FA) to accrue the benefits from the microstructure refinement, no attempt has been made to study the deflection behavior and drying shrinkage of concrete that is devoid of aggregates while supplementing 80% of cement with class F fly ash (F-FA). Two types of concrete are used to cast full-scale reinforced concrete (RC) beams of size 150×300×2200 mm. The first type is a novel no aggregate concrete (NAC) made up of 80% F-FA and 20% ordinary Portland cement (OPC). The second type is high-volume fly ash self-compacting concrete (HVFASCC), which has 60% F-FA as a cement supplement and is equivalent in compressive strength to NAC. The NAC is reinforced with polypropylene fibers (PF) in three varying volume fractions: 0.6%, 0.8%, and 1.0%. All the beams are tested under a simply supported four-point loading condition. The drying shrinkage strain and mass loss are measured for prisms of size 75×75×300 mm up to 220 days exposed at 20% relative humidity (RH) and 50 ºC temperature in a humidity oven for all the mixes. The mechanical properties are also assessed along with the water absorption (sorptivity). The results indicate that adding PF to the beams with NAC delays the formation of the first crack and improves the peak load, the ultimate load, and the ductility of the NAC beam. Additionally, the beams with PF exhibit lower mid-span deflection and ductile failure mode, improving the overall structural performance. Regarding drying shrinkage, the HVFASCC prisms record the lowest shrinkage strains of all mixes. Adding PF to NAC increases the initial and ultimate drying shrinkage strains. However, adding PF to NAC inhibits the rate of shrinkage strain over the test duration. This research enhances understanding of how PF affects no-aggregate concrete behavior, paving the way for more comprehensive construction materials.

Enhancement in thermo-hydraulic performance of ceramic-based disk heat sink with fractal micro-channels via double layering, hybrid nanofluids, and cross-sectional convergence

The focus of this paper is to further improve the thermo-hydraulic performance of a disk heat sink with fractal-like microchannels by introducing four distinct modifications: incorporating convergent cross-sections in microchannels, implementing double layering, utilizing a high-conductivity material (AlN ceramic) for the heat sink, and integrating hybrid nanofluids. Hybrid nanofluids, encompassing Aluminum Oxide-Graphene, Aluminum Oxide-Copper, and Copper-Graphene, each with varying volume fractions and an overall volume fraction of 2 % and 4 %, were systematically evaluated. The cumulative impact of these modifications on the four levels fractal-like microchannel heat sink's thermo-hydraulic performance was rigorously assessed through numerical simulations. The flow rate ranges from 300 to 600 ml/min, corresponding to an inlet Reynolds number in the range of 3014 to 6018.The findings reveal that the increase around 10 % in Nusselt number can be achieved through implementing converging cross-sections at levels 3 and 4. Substituting silicon with AlN ceramic leads to a reduction in maximum temperature from 1.85 to 2.58 ℃, depending on the flow rate. Under a heat flux of 40 W/cm2, double layering can reduce thermal resistance by 0.2. Most effective configuration involves a double-layered fractal microchannel with convergent cross-sections at levels 3 and 4, employing AlN ceramic as the material, and utilizing a hybrid water-based nanofluid with a volume fraction of Cu 3 %-Al2O3 1 %. This configuration achieves a notable reduction in maximum temperature by 11.1 °C and 17.97 °C under heat fluxes of 40 and 80 W/cm2, respectively, at a volumetric flow rate of 300 ml/min.

Investigation of the influence of morphology on thermal conductivity in hexagonal honeycomb structures and computational models with varied volume fraction and conductivity ratio

The effective thermal conductivity (ETC) is a critical parameter for simulating macroscopic heat transfer processes in composite materials, which estimation is particularly critical where the thermal conductivity of the composite phases is completely different. The huge difference in thermal conductivity of the composite phases makes their volume fraction modulation a classical way to reach the desired thermal conductivity. Nevertheless, the typical manufacturing process of honeycomb cellular structures allows various degrees of stretching of the structure, leading to various honeycomb geometries. In these ‘real’ structures some of the honeycomb wall sides are twice as thick as other parts, modifying the symmetry of the system with respect to honeycomb with uniform wall side thickness. A noticeable example of these composites is that of a hexagonal metallic honeycomb structure filled with phase change material (PCM) which is a widely utilized material in the field of thermal storage and thermal management by exploiting the heat absorbed/released by the PCM phase during its melting/solidification. While the thermal response of a PCM composite during a thermal cycle is not only defined by thermal conductivity (but also by cell size), this represents the basis for the with the optimization of a system based on a composite PCM.For this reason, in this study, steady-state simulations of heat transfer in unit honeycomb cells in different directions perpendicular to the cell axis are conducted to quantify the impact of morphology on the thermal property of the different wall types within honeycomb structures. The results demonstrate that in both SHS and DHS, the porosity exhibiting maximum anisotropy of ETC decreases as the thermal conductivity ratio increases. Moreover, simple predictive models for calculating the ETC in all directions are proposed for each type of honeycomb, considering a wide range of porosity and thermal conductivity ratio, with a relative error limited to 2 %.

Experimental study on the disturbance of microbubble liquid jets

The presence of microbubble significantly influences the rheological properties of a jet, thereby considerably increasing the complexity of the jet instability problem. However, the instability of microbubble jets has been rarely studied, and their breakup mechanism remains obscure. The present study was focused on conducting a comprehensive analysis of bubble jet flows. A high-precision experimental system was constructed to extract the time-series signals of each cross-sectional profile along the axial direction of a jet. Glycerol solutions with three different bubble volume fractions were prepared, and the standard deviation, spectral relationship, and nonlinear dynamical behavior (i.e., autocorrelation, phase space trajectory, Poincaré section, and Lyapunov exponent) were studied. The detailed development process of small surface disturbances in space was assessed, and the influence of variations in the bubble volume fraction on the nonlinear dynamics of the jet was examined. The results demonstrate that microbubbles can significantly change the energy transfer relationship between various sections of a jet and enhance the periodicity of the signal.

Debris-induced consequences on turbulence and vorticity in solar photovoltaic module-generated array wakes

Particle-laden flows in solar photovoltaic (PV) systems are inevitable, where wind-swept debris in open environments are carried by high winds and turbulence, coating panel surfaces or damaging structures. Particle deposition, or soiling, is a well-known issue for large-scale plants which rely on uninhibited solar rays for optimal production. But understanding the mechanisms leading to soiling requires a physical and fluid dynamics-centered focus, since turbulence dominates PV panel wakes and is also known to alter particle concentration and trajectories. This study presents an experimental campaign toward consequences of particle-laden flow between two model PV panels using time-resolved particle image velocimetry. The model array was subjected to varied particle volume fractions, including a tracer particle case and a water droplet case. Characterization of mean velocity, turbulence statistics, and mean kinetic energy within the single phase and, separately, particle phase flows showed modified features due to particle inertia. Images captured at a frequency of 1 kHz in the near wake of the upstream panel allow for a first experimental look at vorticity and convective velocity of vortex structures for single-phase and particle-phase flows which are crucial to debris transport and soiling in PV environments.

A numerical investigation for the development of functionally graded Ti/HA tibial implant for total ankle replacement: Influence of material gradation law and volume fraction index.

Stress shielding is one of the major concerns for total ankle replacement implants nowadays, because it is responsible for implant-induced bone resorption. The bone resorption contributes to the aseptic loosening and failure of ankle implants in later stages. To reduce the stress shielding, improvements can be made in the implant material by decreasing the elastic mismatch between the implant and the tibia bone. This study proposes a new functionally graded material (FGM) based tibial implant for minimizing the problem of stress shielding. Three-dimensional finite element (FE) models of the intact tibia and the implanted tibiae were created to study the influence of material gradation law and volume fraction index on stress shielding and implant-bone micromotion. Different implant materials were considered that is, cobalt-chromium, titanium (Ti), and FGM with Ti at the bottom and hydroxyapatite (HA) at the top. The FE models of FGM implants were generated by using different volume fractions and the rule of mixtures. The rule of mixtures was used to calculate the FGM properties based on the local volume fraction. The volume fraction was defined by using exponential, power, and sigmoid laws. For the power and sigmoid law varying volume fraction indices (0.1, 0.2, 0.5, 1, 2, and 5) were considered. The geometry resembling STAR® ankle system tibial implant was considered for the present study. The results indicate that FGMs lower stress shielding but also marginally increase implant-bone micromotion; however, the values were within the acceptable limit for bone ingrowth. It is observed that the material gradation law and volume fraction index influence the performance of FGM tibial implants. The tibial implant composed of FGM using power law with a volume fraction index of 0.1 was the preferred option because it showed the least stress shielding.

Pengaruh Fraksi Volume Serat Terhadap Peningkatan Kekuatan Impak dan Kekuatan Tarik Komposit Berpenguat Serat Daun Nanas (Ananas Cosmosus)

A composite is a technical material that is made by combining two or more materials that have different properties to become a new material with different properties. Natural fibers used as composite reinforcement are more environmentally friendly and biodegradable. The use of natural fibers as composite reinforcement in recent years has experienced very rapid development. One of them is pineapple leaf fiber. The aim of this research is to determine the effect of fiber volume fraction and NaOH immersion on the mechanical properties (Tensile Strength and Impact Strength) of composites reinforced with pineapple leaf fibers with an epoxy matrix. In this research, woven composites were made with variations in volume fraction and NaOH immersion time for the fibers, then tensile tests according to ASTM D-3039 standards and impact tests according to ASTM D256 standards. Based on test results with varying fiber volume fractions of 15%, 20%, and 25%, the strength results increase and decrease. The tensile strength of the composite tends to increase with increasing fiber volume fraction and NaOH immersion. However, the longer the soaking time, namely 4 hours, the tensile strength of the composite tends to decrease. The most optimal average value of tensile strength is at a fiber volume fraction of 25% with fiber soaking for 2 hours with a value of 23.07 MPa and the lowest average value of tensile strength is at a fiber volume fraction of 15% with fiber soaking for 4 hours with value 11.31 MPa. Meanwhile, the highest average impact value was owned by a composite with a fiber volume fraction of 20% without soaking, namely 0.0589 j/mm2 and the lowest impact value was with a fiber volume fraction of 20% with fiber soaking for 4 hours, namely 0.0124 j/mm2.

Effect of graphene reinforcement on the tensile and flexural properties of thermoplastic polyurethane nanocomposite using experimental and simulation approach

ABSTRACT This study investigates the integration of graphene (Gr) nanoparticles into polyurethane (PU) matrices to enhance mechanical properties, focusing on Young’s modulus, tensile strength, and flexural strength. Utilising a Representative Volume Element (RVE) analysis with 1 × 1 × 1 μm dimensions, the research evaluates PU/Gr composites at varying volume fractions. Results indicate substantial improvements in mechanical properties, with the 0.05 PU/Gr composite exhibiting the highest enhancements, including a 25% increase in Young’s modulus and 26% and 31% enhancements in tensile and flexural strengths, respectively, compared to pure PU. Fractography confirms the transition from ductile to brittle behaviour with Gr incorporation. The RVE method accurately predicts Young’s modulus, aligning closely with experimental and micromechanical model data. Additionally, ANSYS simulation tests show results within a 10% error margin. The findings suggest significant potential for the development of high-performance composite materials applicable across industries like aerospace, automotive, and construction.

Heat transfer treatment of system during freezing with implement of nanoparticles

The present attempt investigates solidification through a tank equipped with T-shaped fins, a crucial aspect of cold storage technology. Utilizing the Finite Element Method (FEM) for simulation, implementation of a mesh adaptation technique enhances the accuracy of modeling. Equations are derived based on the assumption of neglecting velocity effects during solidification, simplifying the mathematical framework for analysis. Validation of the numerical approach is conducted through comparisons with previously published works, affirming the reliability of the methodology. A notable aspect of the study is the utilization of nanosized powders dispersed within the water, serving to bolster system performance. This innovative approach enhances water conductivity, thereby augmenting the rate of cold storage. Employing powders with a greater shape factor yields promising results, leading to a discernible decrease in completion time by approximately 10.6 %, attributed to heightened conductivity facilitated by the nanomaterial. Furthermore, the investigation explores the impact of varying volume fractions of particles on solidification time, revealing a significant reduction of approximately 32.78 % with the implementation of higher particle volumes.

Utilizing Ragone framework for optimized phase change material-based heat sink design in electronic cooling applications

This study explores the latent thermal energy storage potential of an organic phase change material with porous copper foam and its applicability in electronic cooling under varying heat load conditions. The organic phase change material, n-eicosane, is known for its inherently low thermal conductivity of 0.15 W/mK, rendering it vulnerable during power spikes despite its abundant latent heat energy for phase transition from solid to liquid. Porous copper foams are often integrated into n-eicosane to enhance the composite's thermal conductivity. However, the volume fraction of the phase change material in the porous foam that optimally improves the thermal performance can be dependent on the boundary condition, the cut-off temperature, and the thickness. A finite difference numerical model was developed and utilized to ascertain the energy consumption for the composite of n-eicosane with two kinds of porous copper foam with varying porosity under different heat rates, cut-off temperatures, and thickness. In addition, the results are compared with a metallic phase change material (gallium), a material chosen with a similar melting point but significantly high thermal conductivity and volumetric latent heat. For validation of the numerical model and to experimentally verify the effect of boundary condition (heat rate), experimental investigation was performed for n-eicosane and high porosity copper foam composite at varying heat rates to observe its melting and solidification behaviors during continuous operation until a cut-off temperature of 70 °C is reached. Experiments reveal that heat rate influences the amount of latent energy storage capability until a cutoff temperature is reached. For broad comparison, the numerical model was used to obtain the accessed energy and power density and generate thermal Ragone plots to compare and characterize pure gallium and n-eicosane - porous foam composite with varying volume fractions, cutoff temperature, and thickness under volumetric and gravimetric constraints. Overall, the proposed framework in the form of thermal Ragone plots effectively delineates the optimal points for various combinations of heat rate, cut-off point, and aspect ratio, affirming its utility for comprehensive design guidelines for PCM-based composites for electronic cooling applications

Evaluating the effect of functionally graded materials on bone remodeling around dental implants

ObjectivesThis study evaluates the potential for osseointegration and remodeling of customized dental implants made from Titanium-Hydroxyapatite Functionally Graded Material (Ti-HAP FGM) with optimized geometry, using the finite element method (FEM). MethodsThe study utilized CT scan images to model and assemble various geometrical designs of dental implants in a mandibular slice. The mechanical properties of Ti-HAP FGMs were computed by varying volume fractions (VF) of hydroxyapatite (0–20%), and a bone remodeling algorithm was used to evaluate the biomechanical characteristics of the ultimate bone configuration in the peri-implant tissue. ResultsThe findings of the FEA reveal that osseointegration improves with changes in the density and mechanical properties of the bone surrounding Ti-HAP implants, which are influenced by the varying VF of hydroxyapatite in the FGM. SignificanceIncreasing the hydroxyapatite fraction improves osseointegration, and appropriate length and diameter selection of Ti-HAP dental implants contribute to their stability and longevity.

Fabrication and characterization of graphene oxide (GO)-modified micro-nano composite magnetic microspheres

Addressing the contradiction between the magneto-rheological properties and dispersion stability of MRFs poses a significant challenge in the preparation process. This paper proposes a micro-nano composite material design scheme using graphene oxide as a grafting agent to encapsulate nanoscale magnetite (Fe3O4) particles onto the surface of carbonyl iron powders. The prepared micro-nano composite magnetic microspheres achieve a reduction in density for enhanced stability while ensuring no compromise in magnetic performance. The effectiveness of the preparation process is ensured through the analysis of the microscopic morphology, crystal structure, and elemental characteristics of all process products using Field Emission Scanning Electron Microscopy (FE-SEM), powder X-ray diffraction (XRD), Raman Spectroscopy, and Fourier Transform Infrared Spectroscopy (FTIR). To obtain MRFs more suitable for magneto-rheological damper applications, this study synthesized micro-nano composite MRFs with different base liquids and varying volume fractions. The stability and magneto-rheological properties of each sample were analyzed through visual techniques and rheological testing platforms. The results indicated that micro-nano composite MRFs based on 40% to 50% silicone oil exhibit superior stability in various aspects, including sedimentation stability, redispersion stability, and temperature stability. Additionally, the micro-nano composite MRFs demonstrated significantly enhanced magnetic performance compared to pure micrometer-sized, pure nanometer-sized, and micro-nano hybrid MRFs.