Enhanced knowledge of the transient behavior and characteristics of electrorheological (ER) fluids subject to time dependent electric fields carries the potential to advance the design of fast actuated hydraulic devices. In this study, the dynamic response of electrorheological fluid flows in rectilinear microchannels was investigated experimentally. Using high-speed microscopic imaging, the evolution of particle aggregates in ER fluids subjected to temporally stepwise electric fields was visualized. Nonuniform growth of the particle structures in the channel was observed and correlated to field strength and flow rate. Two competing time scales for structure growth were identified. Guided by experimental observations, we develop a phenomenological model to quantitatively describe and predict the evolution of microscale structures and the concomitant induced pressure gradient.

Electrorheological fluids offer potential for developing rapidly actuated hydraulic devices where shear forces or pressure-driven flow are present. In this study, the Bingham yield stress of electrorheological fluids with different particle volume fractions is investigated experimentally in wall-driven and pressuredriven flow modes using measurements in a parallel-plate rheometer and a microfluidic channel, respectively. A modified Krieger-Dougherty model can be used to describe the effects of the particle volume fraction on the yield stress and is in good agreement with the viscometric data. However, significant yield hardening in pressure-driven channel flow is observed and attributed to an increase and eventual saturation of the particle volume fraction in the channel. A phenomenological physical model linking the densification and consequent microstructure to the ratio of the particle aggregation time scale compared to the convective time scale is presented and used to predict the enhancement in yield stress in channel flow, enabling us to reconcile discrepancies in the literature between wall-driven and pressure-driven flows.

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