In this research, crosslinked polyethylene (XLPE) is developed with selective content of dicumyl peroxide (DCP), and the influence of microstructural properties and chemical composition on the mechanical and direct current (DC) dielectric properties are investigated. The measurements for the microstructural analysis are taken by gel permeation chromatography (GPC), differential scanning calorimetry (DSC), gel content test and Fourier transform infrared (FTIR). The mechanical properties of XLPE are evaluated by hot-set test. The results of microstructural and chemical composition show that the increase in DCP content increases the crosslinking degree from 74.3% to 81.6%, reduces the crystallinity/lamella thickness from 36.8% to 35.5%/7.6–7.1 nm, reduces the average molecular weight between two crosslinks by 0.01 kg/mol and reduces the oxidation level/carbonyl index. The increase in DCP in XLPE samples decreases the permanent elongation from 2.2% to 0% and elongation rate from 300% to 80% of the cable insulation. The rise in DCP content increases the crosslinking degree due to which the DC resistivity and activation energy is increased. The DC breakdown strength at 30–90 °C is increased due to the increase in crosslinking degree and reduction in carbonyl index/oxidation level. The space charge accumulation is measured at 30 °C under 20–60 kV/mm, resulting in less homo-charges and hetero-charges with the increase in DCP. It is proven that the role of appropriate DCP content is vital in increasing the DC dielectric performance, internal material characteristics and mechanical performance of XLPE.

The flashover strength of epoxy (EP) insulations in the High voltage direct current applications of future energy grids can be improved by tailoring their surface condition. This work aims to improve the DC surface flashover characteristics of EP after being treated with sandpaper of different gradings. Samples with virgin EP and homogenously modified EP considering varying surface roughness ( R _a = 0.54, 3.16, 5.24, and 8.35 μm) are prepared. Different experimental characterisations, such as water contact angle, surface intrinsic conductivity, surface voltages, flashover strength, and trap distributions are conducted and evaluated to analyse the difference between virgin and treated EP. Moreover, based on the obtained experimental results of homogenously treated EP and theoretical analysis, the concept of surface functionally graded materials (SFGMs) is put forward. The flashover voltages of homogenously treated EP are augmented significantly compared to virgin EP regardless of the voltage polarity and enhanced by enhancing the surface roughness. The sample T _Model‐C with SFGM design shows a 45.02% and 43.75% improvement in the negative and positive flashover voltages than that of the virgin EP. In the end, COMSOL simulations are conducted to justify the experimental findings and to analyse the difference between virgin and modified samples in terms of electric field distribution.