Abstract: A slurry is formed of particles of a non-magnetic oxide of iron (.alpha.-Fe.sub.2 O.sub.3), an oil carrier liquid and a surfactant. The slurry is then processed in an attrition mill where kinetic energy is applied to the slurry to convert the .alpha.-Fe.sub.2 O.sub.3 particles to magnetic iron oxide particles to form an oil-based ferrofluid. In order to increase the saturation magnetization of the resulting ferrofluid, a beneficial agent is brought into contact with the slurry during processing in the attrition mill. The beneficial agent can be a magnetic material, such as elemental iron, or can be water. A ferrofluid can also be formed by creating a powder of surfactant-coated magnetic particles and using an attrition mill to coat the particles with a second surfactant and suspend the coated particles in a carrier liquid.

Abstract: A ferrofluid manufacturing process applies energy to a nonmagnetic .alpha.-Fe.sub.2 O.sub.3 starting material to render it magnetic and suitable for use in a ferrofluid. The material is placed, together with a solvent and a surfactant, in a commercial attrition mill where the mill action converts the non-magnetic particles to magnetic particles. In order to eliminate a solvent replacement step which is necessary with oil carrier liquids, water is used as the grinding solvent and as the ferrofluid carrier liquid. The resulting water-based ferrofluid has a high saturation magnetization, low viscosity and good colloidal stability. Using the inventive method, a large volume of fluid can inexpensively be synthesized in a short time.

Abstract: A ferrofluid composition comprising a colloidal dispersion of finely divided magnetic particles in a silicone oil carrier in which the surfaces of the magnetic particles are modified with (a) a first surfactant comprising a hydrocarbon having at least one polar group and (b) a second surfactant comprising a silicone oil surfactant having at least one polar group and which is soluble in the silicone oil carrier.