• • Mason number scaling successfully unified rheological responses across magnetic field strengths, indicating that magnetic and hydrodynamic interactions dominate over thermodynamic and colloidal forces, enabling predictive control of flow behavior in ferrofluid-based devices.
• • Increasing silica concentration or particle size raises the critical Mason number, reflecting more stable field-induced structures; this allows tuning of the magnetic field threshold required for structural transitions, critical for designing responsive seals and dampers.
• • High silica concentrations significantly enhance shear thinning (larger flow index), while particle size has little effect on the flow index; this decoupling enables independent control of viscosity profile and structural stability, optimizing formulations for specific applications.
• • Macroscopic models accurately describe normalized Bingham yield stress, whereas microscopic models better predict normalized static yield stress, revealing distinct yielding mechanisms that inform the selection of constitutive models for engineering design.