Magnetoactive (MA) foam, with its tunable mechanical properties and magnetostriction, has the potential to be used for the development of soft sensor technology. However, researchers have found that its mechanical properties and magnetostriction are morphologically dependent, thereby limiting its capabilities for dexterous manipulation. Thus, in this work, MA foam was developed with additional capabilities for controlling its magnetostriction, normal force, storage modulus, shear stress and torque by manipulating the concentration of carbonyl iron particles (CIPs) and the magnetic field with regard to morphological changes. MA foams were prepared with three weight percentages of CIPs, namely, 35 wt.%, 55 wt.% and 75 wt.%, and three different modes, namely, zero shear, constant shear and various shears. The results showed that the MA foam with 75 wt.% of CIPs enhanced the normal force sensitivity and positive magnetostriction sensitivity by up to 97% and 85%, respectively. Moreover, the sensitivities of the storage modulus, torque and shear stress were 8.97 Pa/mT, 0.021 µN/mT, and 0.0096 Pa/mT, respectively. Meanwhile, the magnetic dipolar interaction between the CIPs was capable of changing the property of MA foam from a positive to a negative magnetostriction under various shear strains with a low loss of energy. Therefore, it is believed that this kind of highly sensitive MA foam can potentially be implemented in future soft sensor systems.
Carbonyl iron particles (CIPs) is one of the key components in magnetic rubber, known as magnetorheological elastomer (MRE). Apart from the influence of their sizes and concentrations, the role of the particle' shape is pronounced worthy of the attention for the MRE performance. However, the usage of CIPs in MRE during long-term applications may lead to corrosion effects on the embedded CIPs, which significantly affects the performance of devices or systems utilizing MRE. Hence, the distinctions between the two types of MRE embedded in different shapes of spherical and plate-like CIPs, at both conditions of non-corroded and corroded CIPs were investigated in terms of the field-dependent rheological properties of MRE. The plate-like shape was produced from spherical CIPs through a milling process using a rotary ball mill. Then, both shapes of CIPs individually subjected to an accelerated corrosion test in diluted hydrochloric (HCl) at different concentrations, particularly at 0.5, 1.0, and 1.5 vol.% for 30 min of immersion time. Eight samples of CIPs, including non-corroded for both CIPs shapes, were characterized in terms of a morphological study by field emission scanning electron microscope (FESEM) and magnetic properties via vibrating sample magnetometer (VSM). The field-dependent rheological properties of MREs were analyzed the change in the dynamic modulus behavior of MREs via rheometer. From the application perspective, this finding may be useful for the system to be considered that provide an idea to prolong the performance MRE by utilizing the different shapes of CIPs even when the material is fading.