Uncertainty Propagation for Power-Law, Bingham, and Casson Fluids: A Comparative Stochastic Analysis of a Class of Non-Newtonian Fluids in Rectangular Ducts

This study presents a novel framework for uncertainty propagation in power-law, Bingham, and Casson fluids through rectangular ducts under stochastic viscosity (Case I) and pressure gradient conditions (Case II). Using the computationally efficient Stochastic Finite Difference Method with Homogeneous Chaos (SFDHC), validated via comparison with quasi-Monte Carlo simulations, we demonstrate significantly lower computational costs across varying Coefficients of Variation (COVs). For viscosity uncertainty (Case I), results show a 0.54–2.8% increase in mean maximum velocity with standard deviations reaching 75.3–82.5% of the COV, where the power-law model exhibits the greatest sensitivity (velocity variations spanning 71.2–177.3% of the mean at COV = 20%). Pressure gradient uncertainty (Case II) preserves mean velocities but produces narrower and symmetric distributions. We systematically evaluate the effects of aspect ratio, yield stress, and flow behavior index on the stochastic velocity response of each fluid. Moreover, our analysis pioneers a performance hierarchy: Herschel–Bulkley fluids show the highest mean and standard deviation of maximum velocity, followed by power-law, Robertson–Stiff, Bingham, and Casson models. A key finding is the extreme fluctuation of the Robertson–Stiff model, which exhibits the most drastic deviations, reaching up to 177% of the average velocity. The significance of fluid-specific stochastic analysis in duct system design is underscored by these results. This is especially critical for non-Newtonian flows, where system performance and reliability are greatly impacted by uncertainties in viscosity and pressure gradient, which reflect actual operational variations.