Effect of Ferromagnetic Metal Base on Friction and Wear of 3D-Printed Aluminum Alloy Surface under Magnetorheological Fluid Action

Abstract

This study aimed to enhance the friction performance and controllable range of magnetorheological devices by investigating the impact of different materials on the tribological properties within a magnetorheological fluid (MRF) under the influence of a magnetic field. A novel friction-combined structure was proposed, consisting of a ferromagnetic metal base and a metal surface shell fabricated using 3D printing technology. The design offered several advantages: the ferromagnetic base significantly improved the magnetic field control range, the 3D-printed surface shell allowed easy replacement with different materials and textures, and it reduced both development and application costs. In this experimental study, composite samples consisting of metal 3D-printed surfaces and substrates made of different materials were used to evaluate the friction and wear characteristics of the MRF under different magnetic field conditions. Computer numerical control (CNC)-machined surfaces were also included for comparison. The results showed that the ferromagnetic matrix affected the magnetic field size and distribution of the energized coil, resulting in an increase in the friction coefficient, but also an increase in wear. Furthermore, the combination of 3D-printed surfaces with ferromagnetic substrates had a more pronounced effect on the friction coefficient compared to CNC-machined surfaces. Based on these findings, this research concluded that 3D-printed surfaces outperform CNC-machined surfaces in this specific environment. In addition, the proposed design, which combined ferromagnetic bases with 3D-printed surfaces, shows potential for improving the friction performance of friction components. The increase rate of friction coefficient from 0.1459 at no current to 0.2089 at 2.5A was 43.18%. This offers a novel application of 3D printing technology in magnetorheological devices.