Tunable magnetophoretic method for distinguishing and separating wear debris particles in an Fe‐PDMS‐based microfluidic chip

Abstract Wear debris analysis provides an early warning of mechanical transmission system aging and wear fault diagnosis, which has been widely used in machine health monitoring. The ability to detect and distinguish the ferromagnetic and nonmagnetic debris in oil is becoming an effective way to assess the health status of machinery. In this work, an Fe‐poly(dimethylsiloxane) (PDMS)‐based magnetophoretic method for the continuous separation of ferromagnetic iron particles by diameter and the isolation of ferromagnetic particles and nonmagnetic particles with similar diameter by type is developed. The particles experience magnetophoretic effects when passing through the vicinity of the Fe‐PDMS where the strongest gradient of the magnetic fields exists. By choosing a relatively short distance between the magnet and the sidewall of the horizontal main channel and the length of Fe‐PDMS with controlled particles flow rate, the diameter‐dependent separation of ferromagnetic iron particles, that is, smaller than 7 µm, in the range of 8–12 µm, and larger than 14 µm, and the isolation of ferromagnetic iron particles and nonmagnetic aluminum particles based on opposite magnetophoretic behaviors by types are demonstrated, providing a potential method for the detection of wear debris particles with a high sensitivity and resolution and the diagnostic of mechanical system.