1. Introduction
The increasing power demand in conventional power systems due to modernization has led to the growing complexity of power grids with the integration of distributed power sources such as renewable energy and energy storage systems. To accommodate various power sources and loads connecting to the grid, installation of various type of power assets and equipment would be required [
1]. For stable and safe operation of the power grid, it is essential that such power assets and equipment are designed to show high level of reliability. Typically, the reliability and safety of power equipment are determined by electrical insulation, thus necessitating research on the insulation performance of various electrical materials [
2]. Epoxy resin, known for its excellent electrical and thermal properties, has been widely used as an insulating material in power equipment. In order to improve performance of electrical insulation, the approach of developing epoxy composites that include functional fillers have been considered.
The effectiveness of both epoxy micro-composites and epoxy nanocomposites have been reported. Examples of fillers used in epoxy composites include silica (SiO
2), alumina (Al
2O
3), and titania (TiO
2) [
3]. As a more significant improvement in performance could be obtained by adding a smaller amount of filler compared to epoxy micro-composites, epoxy nano-composites have received attention. According to [
3], nano-sized silica particles contribute to increased performance of thermal conductivity, insulation strength, and PD resistance of epoxy-based insulation materials. Thanks to such improvement, the effectiveness of SiO
2/epoxy nano-composites for applications that involve high level of electrical stress (e.g., HVAC power cables and insulation of electric machines) were studied. In addition, nano-sized alumina fillers improve PD resistance and are mainly applied for miniaturization in rotating machines and winding insulation. Alumina fillers are also known for enhancing mechanical properties. As a result, alumina fillers are applied in gas-insulated switchgear (GIS) spacers, playing a critical role in high-voltage system insulation and providing mechanical support for power equipment [
4]. Further research on epoxy-alumina nano-composites has been performed as follows. Asokan et al. [
5] investigated the influence of interfacial polarization between the polymer and nano particles on the dielectric properties, highlighting its critical role in dielectric relaxation mechanisms. Preetha and Thomas [
6] evaluated the AC breakdown properties of epoxy nano-composites by assessing the insulation durability with varying concentrations of alumina nano-fillers. Furthermore, Pandey and Gupta [
7] emphasized the impact of field treeing degradation mechanisms on the electrical performance of epoxy-alumina nano-composites using electroluminescence techniques.
Despite the advantages of nano sized fillers in improving electrical, mechanical, and thermal properties, micro sized fillers are preferred in actual power equipment insulation design due to economic considerations, ease of processing, and reliability. Metro and Selvaraj [
8] reported that micro-fillers are significantly cheaper than nano-fillers and more suitable for large-scale production, resulting in substantial cost savings. For example, while 3–5 wt% of nano-fillers can achieve similar property improvements, 20–30 wt% of micro-fillers are required; however, the cost-effectiveness of micro-fillers still prevails [
8]. Moreover, micro-fillers have long-established reliability in power equipment [
8], while the long-term performance of nano-fillers is yet to be fully verified. Additionally, Bommegowda et al. [
9] pointed out that nano-fillers have a tendency to agglomerate, complicating the manufacturing process, whereas micro-fillers disperse more easily, simplifying production and improving quality control. Thus, micro-fillers are preferred for power equipment insulation design. Considering such popularity in practical cases and the industry, therefore, this research selected epoxy/Al
2O
3 micro-composites as the test specimens.
Based on its improved mechanical and thermal performance compared to pure epoxy for electrical insulation applications, research on epoxy/Al
2O
3 micro-composites has been performed [
10,
11,
12,
13]. Zhenlian An et al. [
10] compared the effects of fluorination treatment on the surface properties of micro-alumina-filled and unfilled epoxy insulators used in SF
6 gas insulation systems. It was reported that fluorination treatment increased surface hydrophilicity and that the presence of Al
2O
3 particles affected the surface structure and agglomeration state of the composite, thereby changing the surface modification characteristics. In addition, Jin Li et al. [
11] studied the effect of particle agglomeration state on the dielectric breakdown characteristics of epoxy/micro-alumina (Al
2O
3) composites under temperature gradients. It was demonstrated that micro-alumina particles can alter the electrical tree growth path and dielectric breakdown time under high-voltage and high-temperature gradient conditions. Moreover, Wen Cao et al. [
12] analyzed the effects of nano- and micro-alumina (Al
2O
3) and Al(OH)
3 fillers on the flame retardancy properties of epoxy composites in vacuum insulators. In the referenced study [
12], micro-fillers demonstrated better combustion resistance than nano-fillers for Al
2O
3. The prior study [
13] also compared the electrical performance of epoxy resins filled with micro and nano alumina particles. Ref. [
13] emphasized that although nanoparticles more effectively improved the dielectric breakdown resistance, micro alumina is still a favorable choice in terms of large-scale production and cost. Thus, it can be seen that micro-sized Al
2O
3 fillers exhibit superior properties and offer economic advantages when selected.
Meanwhile, high-voltage experiments generally involve statistical processing of experimental data. This is because high-voltage test results can vary due to experimental conditions, environmental factors, and equipment sensitivity. Hence, statistical methods are used to ensure the reliability of the results. In the study by M. Peratchiammal et al. [
14], for instance, statistical methods were employed to evaluate a breakdown voltage (BDV) distribution of insulators when analyzing their flashover characteristics. The BDV data were statistically analyzed to assess various distribution models, and comparisons between experimental data were made to identify better-performing models. Other studies have also applied statistical techniques to high-voltage experimental data [
15,
16,
17]. In the work of U. Khaled and A. Beroual [
15], the goal was to evaluate how the breakdown strength (BDS) of nanofluids changes when various nanoparticles (Fe
3O
4, Al
2O
3, SiO
2) are added to synthetic ester. In that study, the AC breakdown strength (AC-BDS) was measured using standard electrode configurations, and the collected data were analyzed using both normal and Weibull distributions. Their statistical analysis revealed that in most cases, the Weibull distribution fit the data better. Similarly, H. Khelifa et al. [
16] analyzed the probabilities of Weibull and normal distributions for the results of AC breakdown experiments performed on ester synthesized with fullerene and graphene nanofluids. In the research of J. Zhou et al. [
17], the study focused on investigating the effect of moisture accumulation on surface flashover performance in high-voltage insulation systems. They measured the flashover voltage under conditions where moisture was evenly or unevenly distributed on the insulator surface and used statistical techniques to analyze the flashover data under different conditions. In that study, log-normal and gamma distributions were also employed for statistical analysis. In previous studies [
15,
16,
17], Weibull distribution analysis was conducted using the Anderson–Darling (A-D) statistic and
p-values [
18]. The normal distribution analysis, on the other hand, was verified using the Shapiro–Wilk method [
19]. Although several distribution models (e.g., Weibull and normal distribution) have been generally considered as a representative distribution model for statistical processing of electrical breakdown data, it is necessary to validate such an approach based on statistical analysis tools, as to be shown later in this paper.
This paper studied the electrical insulation performance of epoxy/Al2O3 micro-composites. In order to characterize the specimen, measurement of dielectric properties (i.e., permittivity and loss tangent) and electrical breakdown experiments were performed. From the experiment data, it was possible to characterize the dielectric properties and electrical BDS of epoxy/Al2O3 micro-composites. Furthermore, statistical analysis was performed on the data to gain insights on the measurement results and material performance. From such analysis, in particular, the dependence of the specimen permittivity on temperature was observed, and the conformity of electrical breakdown data to several parametric distribution models was observed.
In this study, the conformity of the AC-BDS measurement results of epoxy/Al
2O
3 micro-composites to the laws of normal and Weibull distributions was verified. The Weibull distribution analysis was conducted using the method proposed in [
18]. For the normal distribution analysis, four different methods were employed: Shapiro–Wilk (statistic: W) [
19], Anderson–Darling (statistic: A-D) [
20], Ryan–Joiner (statistic: R-J) [
21], and Kolmogorov–Smirnov (statistic: K-S) [
22]. The
p-values obtained from these methods were used to confirm whether the AC-BDS of epoxy/Al
2O
3 micro-composites satisfied normality. Furthermore, the skewness and kurtosis of the AC-BDS data were analyzed to verify if the shape of the distribution resembled that of a normal distribution. Meanwhile, in the statistical analysis of failure data for insulating materials, distributions such as Weibull, Gumbel, and log-normal are commonly used [
23]. Moreover, other distributions, such as Gaussian normal, double-exponential, Wohlmuth’s two-limit, and gamma, have also been considered for processing high-voltage experiment data [
24]. Therefore, the effectiveness of the distribution models of log-normal, exponential, and gamma for modeling AC-BDS experiment data of epoxy/Al
2O
3 micro-composites were also studied in this paper. The best-fitting distribution for analyzing the AC-BDS of the epoxy/Al
2O
3 micro-composites was selected using the A-D statistics obtained from the distribution analyses.
The remainder of this paper is organized as follows. In
Section 2, the AC-BDS measurement method is presented. Details on the test sample configuration and measurements of the permittivity and the loss tangent are also introduced.
Section 3 introduces the normal distribution and Weibull distribution methods, along with distribution fitting techniques, for statistically analyzing BDS. Experiment results of the dielectric properties and electrical breakdown tests are provided in
Section 4.
Section 5 presents the analysis of the dielectric properties measured under temperature variation in
Section 2 through the use of the
t-test method. Additionally, the goodness-of-fit for log-normal distribution and the inadequacy of the exponential distribution using the A-D test are discussed in
Section 5. Conclusions of the manuscript are provided in the
Section 6.
6. Conclusions
This study analyzed the AC-BDS and dielectric properties of epoxy/Al2O3 micro-composites and verified the experimental data using various statistical methods. The analysis of dielectric properties showed a trend of increasing relative permittivity and dissipation factor with rising temperatures, and the t-test confirmed that these changes were statistically significant. This emphasizes that the insulation performance is sensitive to temperature changes and provides important insights for predicting the behavior of insulating materials in high-temperature environments.
The AC-BDS of the micro-composites was measured using the ramp test (RT) and 60 s step-up test (ST), and the data were analyzed using various statistical distribution models, including normal and Weibull distributions. ST-BDS data fit well with the Weibull distribution, confirmed by p-values greater than 0.05. On the other hand, RT-BDS showed results that were inconsistent with the Weibull distribution, with a p-value of less than 0.05. However, the breakdown voltage values obtained from RT showed good agreement with the Weibull distribution. This is thought to be due to the standard deviation of the thickness of the epoxy/Al2O3 micro-composites. The normal distribution also provided a good fit for the experimental data, with all p-values exceeding the 0.05 threshold. Additionally, the results of the goodness-of-fit test showed that both the log-normal and gamma distributions had p-values greater than the significance level (5%) and exhibited a high degree of fit with low A-D statistics. However, the exponential distribution showed poor conformity, as indicated by higher A-D statistics and p-values lower than 0.05.
In conclusion, the study has provided valuable insights into the breakdown characteristics and dielectric behavior of epoxy/Al2O3 micro-composites. Regarding the dielectric properties, the temperature dependence of both the relative permittivity and the dissipation factor were verified using a statistical analysis approach. The statistical analysis confirmed that the Weibull and normal distributions are appropriate for analyzing the AC-BDS of these materials, while the exponential distribution was found to be less suitable. In addition, the goodness-of-fit test results comparing A-D values revealed that the experimental data (AC-BDS of epoxy/Al2O3 micro-composites) of this research best fits the log-normal distribution. Given that the log-normal distribution is one of the distributions used in the high-voltage field, our research suggests that it may, as in this study’s findings, be more suitable than the normal or Weibull distributions. Further research is planned to explore the behavior of these materials under higher temperatures to ensure reliability in high-voltage insulation applications. Additionally, various statistical analyses will be conducted to assess the lifetime of these materials over extended testing durations.