As basalt fiber has better mechanical properties and stability than glass fiber, cross arms made of continuous basalt-fiber-reinforced epoxy matrix composites are capable of meeting the mechanical requirements in the event of typhoons and broken lines in coastal areas, mountainous areas and other special areas. In this paper, continuous basalt-fiber-reinforced epoxy matrix composites were used to fabricate the core rods and composite cross arms. The results verified that basalt fiber composite cross arms can meet the strict requirements of transmission lines in terms of quality and reliability. In addition to high electrical insulation performance, the flexural modulus and the flexural strength of basalt fiber core rods are 1.8 and 1.06 times those of glass fiber core rods, respectively. Basalt fiber core rods were found to be much better load-bearing components compared to glass fiber core rods. However, the leakage current and the result of scanning electron microscopy (SEM) analysis reveal that the interface bonding strength between basalt fibers and the matrix resin is weak. A 3D reconstruction of micro-CT indicates that the volume of pores inside basalt fiber core rods accounts for 0.0048% of the total volume, which is greater than the 0.0042% of glass fiber rods. Therefore, improving the interface bond between basalt fibers and the resin can further improve the properties of basalt fiber core rods.

Basalt fiber and its resin composites have gradually supplanted traditional steel and glass fiber composites due to their superior strength, heat resistance, and corrosion resistance. However, basalt fiber still has significant flaws that restrict the functionality and use of its composites, such as less active functional groups and poor resin adherence. This study examines the effects of sizing agent on the characteristics of basalt fiber/epoxy resin composites. Epoxy resin emulsion and acrylate emulsion are employed as the primary auxiliary film-forming agents in this study. Polyurethane emulsion with various content levels is also used. The findings indicate that a 1% wt. of polyurethane emulsion concentration produces the greatest results, increasing the composite’s flexural strength, flexural modulus, tensile strength, and interlaminar shear strength by 122%, 34.0%, 102%, and 10.2%, respectively. At the same time, the storage modulus and Tg of the material will decrease. In addition, the breakdown strength can be raised by 112%, and insulation parameters such as leakage current and dielectric loss factor can be decreased by 26.4% and 15.6%, respectively. The effect of sizing agent B is the best.

Epoxy-resin-based composites in the field of current electrical materials often work in high temperature, high humidity or salt spray conditions. In order to improve the operation reliability of the composite insulator cross arm in a high temperature, high humidity and high salt spray environment, and analyze the aging mechanism and performance characteristics of resin, in this paper, wet heat aging and salt spray aging experiments were carried out on the blended resin system composed of bisphenol A type epoxy resin (E-51), aliphatic epoxy modified bisphenol A epoxy resin (2021P/E-51) and dimeric acid modified bisphenol A epoxy resin (EPD-172/E-51). Among them, 10 wt% and 20 wt% of 2021P blend resin and 10 wt% of EPD blend resin have superior thermo-mechanical properties. Under humid and hot conditions, the dielectric loss of 10 wt% EPD blend system before and after aging is 39.9% and 49.5% lower than that of pure E51 resin system, respectively. Under the condition of salt spray, the dielectric loss of 20 wt% and 10 wt% EPD blends decreased by 73.1% and 74.6% after aging. The leakage current of 10 wt% 2021P blend resin and 10 wt% EPD blend resin decreased by 7% and 3.8% before aging, respectively. After aging, they decreased by 3.7% and 2.2%, respectively. The bending strength of 2021P blend resin before and after aging reached 29.3 MPa and 26.6 MPa, respectively. The above three blending resin systems exhibit good electrical properties and good mechanical properties, their ageing resistance performance is strong and they are suitable as the matrix resin of compound cross arm mandrel material.

This paper presents a study that conducted 5000 h of multi-factor aging tests on 10 kV composite crossarms, considering the natural environment in coastal areas and actual power line operations. Various aging conditions, such as voltage, rain, temperature, humidity, salt fog, ultraviolet light, and mechanical stress, were applied during the tests. The research initially analyzed the influence of multi-factor aging on the bending and tensile properties of the full-size composite crossarm. Subsequently, a detailed investigation was carried out to assess the impact of aging on the mechanical properties, electrical insulation properties, and microscopic characteristics of the composite crossarm core bar. Results indicated that the tensile strength and bending strength of the full-size composite crossarm mandrel experienced minimal changes after aging, remaining well within operational requirements. However, the silicone rubber outer sheath’s hydrophobicity decreased, leading to the appearance of cracks and holes on the surface, which provided pathways for moisture and salt infiltration into the mandrel. As a consequence, the bending strength and shear strength of the mandrel material were reduced by 16.5% and 37.7%, respectively. Moreover, the electrical performance test demonstrated a slight change in the mandrel’s leakage current, while the electrical breakdown strength decreased by 22.8%. Microscopic analysis using SEM, three-dimensional CT, and TGA revealed that a small amount of resin matrix decomposed and microcracks appeared on the surface. Additionally, the fiber-matrix interface experienced debonding and cracking, leading to an increased moisture absorption rate of the mandrel material.

Ensuring the long-term electro-mechanical reliability of high-voltage alternating current (HVAC) insulator strings requires a detailed understanding of how multiple environmental and electrical stressors influence the corrosion behavior of hot-dip galvanized steel fittings. In this study, a three-factor, three-level L9(3³) orthogonal accelerated corrosion test was conducted to systematically evaluate the individual and interactive effects of marine salt deposition (0–10 g m⁻² day⁻¹), acetic acid pollution (0–8 µg m⁻³), and 50 Hz AC leakage current (0–10 mA) on miniature pin-type assemblies. A comprehensive post-corrosion characterization approach was employed. The results revealed that chloride loading from salt deposition was the dominant contributor to corrosion. However, the synergistic interaction between salt and leakage current led to an acceleration in zinc depletion compared to the additive effect of the individual factors. A quadratic regression model with a high correlation coefficient was developed to predict corrosion volume per unit area. The findings offer a mechanistic explanation for field-reported failures in coastal power grids and provide actionable guidance for optimizing corrosion-resistant coatings and implementing electrical mitigation strategies.

In coastal hot and humid regions, the steel pin of AC porcelain insulators often suffers from severe electrochemical corrosion due to surface contamination and moisture, leading to insulator string breakage. Contrary to the common belief that AC corrosion is negligible, this study reveals the significant role of the DC component in leakage currents and the synergy of this DC component with localized high current densities in accelerating corrosion, based on field investigations and experiments. Using a simulation model based on the Suwarno equivalent circuit, it is shown that non-linear contamination causes highly non-sinusoidal leakage currents, with total harmonic distortion up to 40% and a DC component of approximately 22%. To mitigate this, a conductive silicone rubber coating is proposed to block moisture and distribute leakage current evenly, keeping surface current density below the critical threshold of 100 A/m². Simulations indicate that a 2 mm thick coating with conductivity around 10⁻⁴ S/m effectively reduces current density to a safe level. Accelerated corrosion tests confirm that this conductive coating significantly suppresses pitting corrosion caused by high current densities, outperforming traditional insulating coatings. This study presents a practical and effective approach for protecting AC insulators in harsh environments, contributing to improved transmission line reliability in high-temperature and high-humidity regions.