The interaction between magnetorheological (MR) fluid particles and the walls of the device that retain the field-responsive fluid is critical as this interaction provides the means for coupling the physical device to the field-controllable properties of the fluid. This interaction is often enhanced in actuators by the use of ferromagnetic walls that generate an attractive force on the particles in the field-on state. In this article, the aggregation dynamics of MR fluid particles and the evolution of the microstructure in pressure-driven flow through ferromagnetic channels are studied using custom-fabricated microfluidic devices with ferromagnetic sidewalls. The aggregation of the particles and the time-dependent evolution in the microstructure is studied in rectilinear, expansion and contraction channel geometries. These observations help identify methods for improving MR actuator design and performance.
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