Aging of epoxy cast insulation with different voltages and environmental stresses

Abstract Power electronic conversion systems introduce different types of voltage stresses on high-voltage epoxy cast insulation in medium-frequency transformers (MFTs), which challenges the reliability of MFTs. The endurance of epoxy insulation at different voltages (AC, DC and pulse) and environmental (thermal and humidity) stresses was studied using encapsulated electrodes in the absence of partial discharge. To assess aging processes and select aging state indicators, various tests including AC breakdown strength (BDE), broadband dielectric spectroscopy, small-angle x-ray scattering (SAXS), Fourier-transform infrared spectroscopy and differential scanning calorimetry (DSC) were first conducted on aged flat samples. The increase of mesoscopic free volume from the SAXS result and local densification (physical aging) of epoxy network from the DSC result were both found. BDE is proved to be sensitive to various aging conditions and thus determined as a test method for encapsulated samples. It is found that the physical aging effect under thermal stress at early aging stages can cause a reversible increase in BDE compared to non-aged samples. This effect can be erased by coupled medium-low electrical stress during aging. In contrast, a sufficiently high electric field will deepen the physical aging extent. Occasional sample failures were observed simultaneously within this process. According to the SAXS and DSC results on flat samples, the failure of encapsulated samples is possibly attributed to the chain fracture around increased mesoscopic free volume during electron bombardment and microcracks generated by interfacial stress release during physical aging. At longer aging periods, the volumetric absorption and diffusion of chemical reactants (oxygen and water) in epoxy networks at high temperatures determines the eventual decrease in BDE, which can be accelerated by the electric field. Ages with different voltage types were gauged by the reduction of BDE compared to pure environmental stress. Bipolar pulses bring heavier aging effects than ACs at the same RMS value. However, the DC component has opposite effects on the BDE with and without thermal stress.