I have an application requiring relatively fast acting(10 to 100Hz) electrically activated fluidic valves that open and close 1mm diameter holes in a 1.6mm thick insulating plate. I am hoping to use an Electrorheological fluid as the working fluid and have plated copper electrode pads on either side of the plate, thereby turning the fluid in the holes into a solid to close the valves when a high voltage is applied. (800V to 1KV?)

I need to choose a recipie for an Electrorheological fluid with a reliable consistency that won't block the holes with lumps or biodegrade, it needs to have fast state transitions to and from a solid, and it needs to be efficient in that it shouldn't require excessively high voltages to operate. The materials should also be available and not excessively expensive.

I am currently considering mixtures of silicone oil with either 50 micron glass beads, or SuperSiv™ 10A (aka 13x zeolite).

As I am new to this field I would welcome any advice about the best materials to use, how to prepare them, and what performance I might reasonably expect, or working voltages I might have to apply