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.