Significantly enhanced flashover voltage of epoxy in vacuum by graded surface roughness modification

Abstract 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.