A Study on Electrical and Mechanical Simulation for Designing Porcelain Insulators with High-

Strength

Se-Won HAN and Han-Goo CHO
Advanced Electrical Material Group, KERI, Changwon, Korea
Tai-Young KIM
Transmission and Substation Department, KEPCO, Seoul, Korea
Dong-Ill LEE and In-Hyuk CHOI
Transmission and Substation Technology Group, KEPRI, Korea,


Abstract : The aluminous porcelain insulator with high
strength was fabricated. The effects of manufacturing
parameters such as sintering temperature, duration time on
mechanical strengths were analysed in a view of the
micorstructural reinforcement. The prime factors which
improve the mechanical strength are the fertilization of
mullite crystal phase and the reinforcement effect of
alumina particles dispersed in matrix phase. The simulation
results of stress modeling on the real aluminous porcelain
insulator by the NASTRAN program indicate that the
maximum compressive stress act on the porcelain part of
cap lip, then the compressive strength value on it is about
240 f/ , which is very lower than the experimental
fractural compressive value, 4500 f/ . The study of
reinforcement mechanism with the thermal stress model of
microstructure shows the alumina particles with low
thermal expansion coefficient compare to matrix materials
act as a barrier protecting the progress of micro-crack, as a
result it governs the improvement of mechanical strengths.

KEYWORDS Aluminous porcelain insulator, Mechanical
characteristics, Microstructure, NASTRAN simulation,
Reinforcement mechanism


I. INTRODUCTION

The most important part of a suspension insulator is the
head portion. When a fail of porcelain insulators happens,
it was known the cap puncture of head is main reason of it.
The fatigue with periodical mechanical stress reaches to
some limit value, then the microstructure crack may be
happened inside porcelain body, as a result of the
decrease of insulation ability, the possibility of cap
puncture increase.

In order to protect such fail problems, firstly it is need to
manufacture a high strength body which is possible to
endure the direct impact and then to design an optimal
porcelain shape mitigating localized stresses. Alumina is
often used to replace the silica, eliminating the microcrcks
around the refractory particles. The strength of porcelain
increases with alumina content, but alumina porcelain must
be fired at higher temperatures if the alumina content is
high. To manufacture aluminous porcelain insulator with
high strength, it is very import to develop processing
parameters, but also to study on the microstructural
reinforcement mechanism of body.
In this study, the aluminous porcelain insulator with high
strength for distribution power line was fabricated. The
effects of manufacturing parameters such as sintering
temperature, duration time on mechanical strengths were
analyzed in a view of the micorstructural reinforcement.

II. EXPERIMENT

The chemical analyses and qualitative mineralogical
compositions of the raw materials used in the preparation
of the experimental porcelain bodies are listed in Table.1.
Clay, kaolins, feldspar and alumina were nixed in the 2:3:3:2
ratio Mixing and wet milling was carried out in a ball mill
and attrition mill to get fine distribution of average size
(10m, 75%) as shown in Figure 2. Test rods were
extruded to 11120 mm, and fired in an oxidizing
atmosphere, using the firing schedule shown in Figure 2.
The fired bodies were subjected to qualitative and
quantitative XRD (X-ray Diffractometry, Phillips, 40kV), the
quantitative XRD being performed with rutile as an internal
standard. The amount of glassy phase was calculated as
the difference from 100%. Microstructures of fracture
surfaces etched 5 min. with 8% HF, successively, were
obtained by SEM(Scanning Electron Microscope, Hitachi
S2700). Microanalysis was performed on polished and
etched samples. In addition, microanalysis of mullite was
also carried out by etching with HF+HCL+NH
3
.


Table 1. Chemical analyses and mineralogical compositions
of raw materials
Constituent Amount(wt%)
SiO
2
59.5
Al
2
O
2
29.5
Fe
2
O
3
0.60
TiO
3
0.25
CaO

0.50
MgO

0.45
K
2
O

3.44
Na
2
O

0.76
Balance -
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Grinding in Water
Filtration(Magnetic separation)
Blending
Filter-Pressing (Cake)
Vacuum Extrusion
Mixing into Slurry Waste(65%)
Maturing
Shaping
Clay Felsper Alumina

Figure 1. Manufacturing process.


Max. HTT Conditions :
Temperature:1200-1350
o
C
Time Period : 2-4 hrs
Max. HTT Conditions :
Temperature:1200-1350
o
C
Time Period : 2-4 hrs
Temperature
Time Period

Figure 2. Firing curve of furnace.

Mechanical characteristics such as flexural strength,
compressive strength and tensile strength were measured
according to ASTM C369-56, ASTM C407-58 and ASTM
D116-44, respectively by using the test machine(Instron
6022). Test samples for thermal properties were prepared
with shape of 443mm, the thermal expansion coefficient
measured according to ASTM D372-56 from room
temperature to 600
o
C. To estimate electrical strength of
samples, breakdown voltage of power frequency was
measured in oil according to ES 131-537, where the volume
resistivity of insulating oil was about 10
10
cm. In this test
standard, it is specified that the puncture fail shall not
happen bellow 90kV. Stress simulation was doing by mean
of NASTRN program.

III. RESULTS and DISCUSSION

3.1 Microstructure and High strength Properties.

XRD patterns with the maximum heat treatment
temperature(from 1250
o
C to1350
o
C) are shown in Figure 3.
These patterns show that the sample treated at 1350
o
C has
larger amount of M(Mullite) crystalline phase then other
samples, but the sample treated at 1250
o
C has larger
amount of Q(Quartz) phase then others. On the other hand,
A(Alumina) crystalline phase decrease with increase of
HTT, it is reason for increasing amount of M(Mullite)
crystalline phase. It was known that M phase growth is
enlarged because of the reaction alumina with silica, and M
phase increase the mechanical strength of porcelain body.

SEM photos of sample sinterd at 1350
o
C, 2hrs are shown
in Figure 4. These micropraph of fracture surface show that
alumina phase and glass phase(or quartz phase) are formed
in matrics and mullite phase likely niddles are distributed
around these phases.

From compressive and flexural strength measurements of
the quartz and alumina porcelains evaluated in other study,
the substitution of alumina for quartz increased the
mechanical strength of the porcelain approximately 1.5
times, agreeing with results reported by various authors.
One possible reason for the large difference in measured
mechanical strengths was due to peripheral fracturing
around the about 8m quartz grains.

The comparison of mechanical properties with HTT
conditions is shown in Figure 5. As it can be seen, it
clearly indicates that bending strength, compression
strength and also tensile strength increase with HTT. In
bending strength, the value of 1550-1730 kg/cm
2
is higher
then values of other products made for distribution power
line. It may be presumed that these reinforcement
phenomenon is due to effects of alumina addition on
mechanical strengths, and it has close relation with the
enlargement of mullite crystalline phase with the increase
of HTT.
1 0 2 0 3 0 4 0 5 0 6 0
0
4 0 0
8 0 0
1 2 0 0
1 6 0 0
0
4 0 0
8 0 0
1 2 0 0
1 6 0 0
0
4 0 0
8 0 0
1 2 0 0
1 6 0 0
2 degree
I
N
T
E
N
S
I
T
Y
M
M
M A
A
A
C
Q
Q
1350
o
C
1300
o
C
1250
o
C

Figure 3. XRD patterns with the maximum heat treatment
temperature.

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1192
1350
o
C, 2Hrs

Figure 4. SEM photos of sample sinterd at 1350
o
C, 2hrs.
1200 1250 1300 1350 1400
1400
1500
1600
1700
1800


B
e
n
d
i
n
g

S
t
r
e
n
g
t
h

[
k
g
f
/
c
m
2
]
HTT [
O
C]
Figure 5. Mechanical properties with HTT conditions.

SEM photographs of the alumina porcelain fracture
surface showed that the fracture traveled through the high
strength alumina grains rather than through the matrix.
This should contribute to an increase in mechanical
strength because the fracture crack overcame the high
strength alumina grains which act as barriers to crack
propagation. One reason why fracture will travel through a
grain in one instance and around a grain and through the
glass matrix in another is explained by examining the
difference in the coefficients of thermal expansion of the
grain and the glass matrix surrounding the grain. If the
thermal expansion coefficient of the grain is less than the
glass matrix, there will be hoop tensile stress between the
particle and matrix. The fracture will be directed toward the
particle equator and it will then either stop, or through the
particle, or around it. Thermal expansion studies of the
glass matrix doped with varying concentrations of mullite
must be evaluated and compared to those of
polycrystalline alumina and quartz before proper
evaluation of fracture paths of the silica and alumina
porcelains can be accomplished.

The comparison of bending strength with sintering
duration time is shown in Figure 6. The bending strength
of body sintered in condition of 2 hours has the about 10%
higher value then it of body sintered in condition of 1
hour. The same as the effect of alumian and mullite phase
on mechanical properties reinforcement with HTT, it is
indicated that more long sintering time fertilize the
formation of mullite phase according to the result of XRD
patterns.
1 2 3 4
1500
1600
1700
1800
1900
2000


B
e
n
d
i
n
g

S
t
r
e
n
g
t
h

[
k
g
f
/
c
m
2
]
Time [Hrs]
Figure 6. The comparison of bending strength with
sintering times.

Characteristics of breakdown voltage in oil of samples
with HTT, presented in Figure 7, indicate that the
breakdown voltage of body sintered at 1350
o
C is about
160kV which is about 20% higher then it of body sintered
at 1250
o
C, and it is a trend similarly to mechanical
properties mentioned above. According to ES-131, it is
specified that the porcelain suspension insulator for
distribution line shall not be puncture bellow breakdown
voltage of 90kV, so these values are enough to endure
electrical impact in the head portion of porcelain insulator.














Figure 7. Characteristics of breakdown voltage in oil with
HTT.

3.2. Reinforcement Mechanism

Let the particle have diameter, d=2a, elastic constants, E
p

(Young s modulus) and
p
(Poisson s ratio) and linear
thermal expansion coefficient,
p
. The surrounding
glass(matrix) has elastic constant, E
pm
and
m
, and
expansion coefficient,
m
. It will be assumed that the strain
point for the glass is at a temperature, T, above ambient.
Because of the spherical symmertry, the only displacement
present is the radial displacements(Ur), and the only
stresses present are the radial stress(
r
), and the hoop
1200 1250 1300 1350 1400
100
120
140
160
180
200


B
r
e
a
k
d
o
w
n

V
o
l
t
a
g
e

i
n

O
i
l

[
k
V
]
HTT [
O
C]
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1193
stress(

). If the expansion coefficients

m
and
p
, differ,
then a pressure(or traction) will develop between the
particle and the surrounding matrix as shown in Figure 8.

A : Hoop Stress
B : Radial Stress

Figure 8. Crack propagation paths

If the condition of interfacial continuity is imposed, it is
impossible to calculate the interfacial pressure and from
this, the stresses in the particle and matrix. The results are
as follows:
Particle :
r
=

= - P
Matrix :
r
= - P(a/r)
3
,

= - P/e(a/r)
3

Where P is the interfacial pressure and r is radial distance
from the center of the particle. The pressure, P, is given
by :
P = -(
p
-
pm
)T/(1/4G
m
) + (1-2
p
) / E
p
Where G
m
=E
m
/2(1+v
m
) is the shear modulus. It is also
possible to calculate the strain energy stored in the particle
and surrounding matrix, and equating this energy to that
required to fracture the particle-matrix interface yields a
particle size criterion for this fracture. For alumina, it will be
assumed that E
p
=3.8510
6
kgf/cm
2
,
p
= 0.3,
p
=710
-6
/C
(T=800C)..

Then P (traction at interface) = - 0.8310
6
kgf/cm
2

rp
(tension) =
p
= 0.8310
6
kgf/cm
2

rm
(radial tension) = 0.83(r/a)
3
10
3
kgf/cm
2

m
(hoop compression) = -0.415(r/a)
3
10
3
kgf/cm
2

Where it fracture displacement is 1% and alumina particle
size is bellow 10 m, then the ratio of strain displacement is
3%, as a result the pressure of paticle is about 800 kgf/cm
2
,
the peressure of matrix is about 400 kgf/cm
2
. These values
are lower then the macro pressure values measured above.

3.3. Stress Simulation of Real Model

With NASTRAN using as tool to simulate stress
properties, firstly, main analysis elements were divided,
then boundary conditions on interface between hetero-
elements were determined. Up to this time, the total cell
number and the node number are 1808 and 4049,
respectively. It is general to apply the axisym axial prime
stress method for analyzing the mechanical properties of
materials with high toughness such as porcelain body and
cement. As Figure 9 can be seen, the stress concentration
is mainly localized at the neck portion of porcelain head, it
is the similar phenomenon as reported in other literatures
that the most high stress are shown at the head side of pin
and the lip side of cap.




















Figure 9. Result of stress simulation by NASTRN

The simulation results of stress modeling on the real
aluminous porcelain insulator by the NASTRAN program
indicate that the maximum compressive stress act on the
porcelain part of cap lip, then the compressive strength
value on it is about 240 f/ , which is very lower than
the experimental fractural compressive value, 4500 f/ .
The study of reinforcement mechanism with the thermal
stress model of microstructure shows the alumina particles
with low thermal expansion coefficient compare to matrix
materials act as a barrier protecting the progress of micro-
crack, as a result it governs the improvement of mechanical
strengths

REFERENCES

(1) J. S. T. Looms, "Insulators for High Voltages," IEE
Power Engineering Series 7, Chap.1, 1988.
(2) K. E. Hamano, Z.E. Nakagawa, and M. Hasegawa,
"Improvement of mechanical strength of porcelain bodies
by fine grinding of raw materials," Journal of the Ceramic
Society of Japan, 100(8), p1066, 1992.
(3) K. H. Schueller, "Microstructure of Steatite as
determined with an electron microscope," Ceramic
Bulletin, 50(5), p511, 1971.
(4) H. J. Oel, A. Engel, and H. Paulus, "Dry body
preparation of high voltage porcelain ," DKG, 66(3/4),
p113, 1989.
(5) J. S. T. Looms "Insulators for High Voltages," IEE
Power Engineering Series 7, Chap.7, 1988.
(6) EPRI Tech. Report EL-0721-SY, RPO 424-01
"Improvement of Electrical Porcelain Insulators," Section2,
1978.
(7) Se-Won HAN E-mail : swhan@keri.re.kr
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