Experimental and Statistical Approach to Detect the Corrosion Rate and Influencing Profiles for Enhancing Corrosion Rate of High-Voltage Insulator Materials

The influence of temperature, pollutant, and pH on the local corrosion rate of insulators installed in industrial, marine, and rural installation sites is investigated based on experimental and statistical investigations. The tensile load test confirms that corroded insulator specimens collected from industrial sites aged more than 10 years represent a minimum fracture load, 19,892 lbs. It was further observed that more than 91.24% and 64.62% corroded insulator specimens suffered from shell break and pin detachment, respectively. The microstructural and XRF analysis reveal that insulator specimens collected from industrial sites (age > 10 years), represented the highest wt% of O (19.2) and lowest wt% of Zn (0.34) among industrial, marine, and rural installation sites. The 3D stationery mechanical simulation reveals that insulator specimens aged > 10 years experienced maximum stress (600 MPa) in the pin-cement interface. Using full two-level factorial designs, temperature, concentration of pollutants, and pH were found significant factors for corrosion rate. The immersion test results further confirm the above-mentioned factors significant for the dissolution behavior of galvanized coating of insulator pin. Following immersion test results, the industrial region shows the highest corrosion rate (5.58–12 µm/year) among all installation sites.