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International Journal on Emerging Technologies (Special Issue on NCRIET-2015) 6(2): 72-78(2015)

ISSN No. (Print) : 0975-8364

ISSN No. (Online) : 2249-3255
Study of HTV Silicone Rubber with Different Concentrations of Filler
ATH
M K Bhagyashree*, K.L. Shivabasappa**, S. Raavichandran*** and Shravan Kumar****
*
Assistant Professor, Department of Chemical Engineering, BKIT Bhalki (KA) India.
**
HOD, Department of Chemical Engineering, SIT Tumkur (KA) India.
***
DGM, BHEL-CTI Bangalore (KA) India.
****
Assistant Professor, Department of Electronics and Communication Engineering, GNDCE, Bidar (KA) India.
(Corresponding author: M K Bhagyashree)

(Published by Research Trend, Website: www.researchtrend.net)

ABSTRACT: It is desirable to develop High Temperature Vulcanizing (HTV) Silicone rubber with optimal
amount of filler Alumina Tri Hydrate (ATH). HTV silicone rubber is used as housing material in composite
insulators for high voltage applications. In the present work, HTV silicone rubber with different
concentrations of filler ATH (0, 40, 50, 60phr (parts per hundred rubber)) was prepared. Physical,
mechanical, electrical and processing properties of these Silicone rubbers were studied and results were
compared. 50phr ATH filler content is optimal and gave the best results. HTV silicone rubber from different
sources and with varying content of ATH filler were kept under natural weather for 300 days for weathering
studies and change in properties were recorded. There was not much variation observed in the properties of
silicone rubber after exposing to natural weather. Physical and mechanical properties increased at the
beginning and remained constant. There was no erosion observed on the silicone rubber samples and all the
samples withstood the applied voltage of 4.5kV during tracking and erosion test.
Key words: HTV silicone rubber, ATH, Hydrophobicity
I. INTRODUCTION
II. MATERIALS AND METHODS
Earlier porcelain and glass insulators were used for
high voltage outdoor applications such as sub-stations A. Materials
and distribution and transmission lines. Composite Silicone rubber compound without ATH-IS 0A,
insulators have gained great importance in recent years silicone rubber compound with 40 phr ATH- IS 40A,
in the field of insulation technology for medium and silicone rubber compound with 50 phr ATH- IS 50A,
high-voltage transmission lines and substations. silicone rubber compound with 60 phr ATH- IS 60A.
Composite insulators consist of mainly three HTV silicone rubber and ATH were got from
components i.e., core material, housing material and company i-Silicone.
end fittings. Core material is load-bearing Fiber Glass All the rubber samples were prepared by compression
Reinforced Plastic (FRP) rod covered by housing molding with a pressure of 160 mmHg, curing
material such as polymeric weather sheds made of temperature of 160ºC and curing time of 10 minutes.
silicone rubber and fit with metal end fittings.
Composite insulators have many advantages in B. Methods
Specific Gravity. Specific gravity of samples was
comparison to porcelain or glass insulators such as
determined by using Electronic Densimeter (EW-
light weight, easy handling, better resistance to break
300SG by Alfa Mirage). Known amount of cured
and very good performance in highly polluted
environment and low cost. Because of these important rubber sample was placed on the container of the
properties, the composite insulators have gained densimeter and the weight of the sample was stored
then the sample was placed on the water container of
worldwide importance and are considered the primary
the densimeter. This test was carried out as per
replacement for porcelain and glass insulators.
reference standard DIN 52479.
 Bhagyashree, Shivabasappa, Raavichandran and Kumar 73

Hardness. Hardness of the samples was determined by Specimen was placed in the grips in the testing
using Durometer of type shore-A (Model number machine, then uniform pulling force was applied on the
Shore-A / RR-ISI5181 by Hiroshima). Rubber samples specimen until it broke down. Tear resistance is
of thickness 6mm were used to measure the hardness. calculated by dividing the force at the point of rupture
The Durometer was pressed against the flat sample and by thickness of the specimen. Three specimens were
hardness was measured. This test was carried out tested and average value was calculated.
according to the reference standard ASTM D 2240. Resistance to tracking and erosion. Test specimen of
Tensile strength and ultimate elongation. Tensile size 150mm x 50mm was cut from 6 mm thick rubber
strength and ultimate elongation were determined by sample. Equipment Liquid Contaminant Inclined Plane
using dumbbell shaped specimen. The specimen was Tracking and Erosion of Insulating Materials as per
cut from 2 mm rubber sample. Specimen was tested ASTM D-2303 was used for this test. Contaminant
using universal testing machine (Hiroshima). The test solution was prepared by using ammonium chloride and
specimen was fixed between the grips in the testing wetting agent isooctilphenoxypolietoxi ethanol at a
machine and the specimen was pulled steadily at concentration of 0.1% and 0.02% respectively.
specified rate until it breaks. The force exerted on the Resistivity of the contaminant solution was 3.95Ωm
specimen at the time of rupture is the tensile strength of ±0.05Ωm. Test method-1: Constant voltage tracking
the specimen. The percentage increase in the original voltage of 4.5kV of standard IEC-60587 was used.
length of rubber during tensile strength test was noted Specimen was fixed in the equipment and constant
as ultimate elongation. Five specimens were tested and voltage of 4.5kV was applied for 6 h with the
average value was calculated. This test was carried out contaminant flow rate of 0.6 ml/min.
as per standard ASTM D 412. Standard values for different properties of silicone
Tear strength. Test specimens were prepared rubber. For a silicone rubber to be used as housing
according standard ASTM D 624 Die-C. The test material for high voltage applications in composite
specimens were cut from 2 mm thick rubber sample. insulators, it should meet the specified requirements as
Specimen was tested using universal testing machine. shown in Table 1.

Table 1: Standard values for different properties of silicone rubber.

Sl No Property Reference Standard Value

Standard
1 Hardness(Shore-A) ASTM D-2240 61 – 75
2 Specific gravity DIN 52479 1.52 – 1.58
2
3 Tensile strength (N/cm ) ASTM D-412 Minimum 400
4 Ultimate elongation (%) ASTM D-412 Minimum 150
5 Tear strength (N/mm) ASTM D-624, Minimum 13
Die-C
6 Resistance to tracking and IEC 60587, Should withstand the
erosion Method-1 voltage of 4.5kV and
there should not be
Erosion on the surface
7 Surface resistivity(TΩ/cm2) IEC 60093 Minimum 100
8 Volume resistivity (TΩ/cm) IEC 60093 Minimum 100
9 Arc resistance (seconds) ASTM D 495 More than 200
10 Dielectric constant ASTM D 150 Minimum 3.5
 Bhagyashree, Shivabasappa, Raavichandran and Kumar 74

Surface and volume resistivity. Surface and volume Loss and recovery of hydrophobicity. Hydrophobicity
resistivity of the specimen were measured using Mega- of silicone rubber is the property which allows the
ohmmeter. Test specimen of size 100mm x 100mm silicone rubber surface to form the water droplets on the
were cut from 2 mm thick rubber sample. Electrodes surface instead of allowing water to flow continuously.
according standard ASTM D-257 were used for the test. Silicone rubber may lose this property during service
Arc resistance. Arc resistance of the specimen was due to the exposure to electrical discharges and constant
measured using Arc Resistance Tester. Specimen of wetting of the surface. Corona was generated on the
size 12.5mm x 12.5 mm was cut from 2 mm thick surface of silicone rubber samples using the High
rubber sample. Test specimen was placed below the frequency resonant variable voltage corona generator.
electrodes and arc was produced between the two Water was sprayed on the sample to check the surface
electrodes. The distance between the electrodes was hydrophobicity before and after corona generation.
5mm. Time required for the specimen to burn was
noted as arc resistance. III. RESULTS AND DISCUSSION
Dielectric constant. Dielectric constant of specimen
In the following discussion formulation 1, 2, 3, 4
was measured using the Automatic Dielectric Constant
means; Formulation: 1 - IS 0A, 2 - IS 40A, 3 – IS 50A,
test setup. Test specimen of size 100mm x 100mm were
4 – IS 60A
cut from 2 mm thick rubber sample. Electrodes
according to standard ASTM D-257 were used for the Specific gravity
test.

Fig. 1: Specific gravity values for different formulations

Figure 1 shows the specific gravity values for different increased with increased ATH content. Specific gravity
formulations and standard value range of specific of formulation 1 without filler ATH had lower specific
gravity. The specified value for specific gravity of HTV gravity and it increased with the filler ATH
silicone rubber for outdoor application is between 1.52 concentration.
and 1.58. Specific gravity of HTV silicone rubber
Hardness
 Bhagyashree, Shivabasappa, Raavichandran and Kumar 75

Fig. 2. Hardness values for different formulations. Fig. 3. Tensile strength values for different
formulations.
Figure 2 shows the hardness (shore-A) values for
different formulations and standard value range for
hardness. The specified value for hardness of HTV
silicone rubber for outdoor application is between 61
and 75. Formulation 3 with 50phr (parts per hundred
rubber) ATH is considered as standard formulation-
with which the properties of other formulation were
compared. Rubber with hardness below 61 would be
too soft and hardness above 75 would be too hard for
high-voltage outdoor application. Rubber without filler
ATH had lower hardness and hardness increased with
an increase in the filler ATH concentration.
Tensile strength and ultimate elongation. Figure 3 Fig. 4. Ultimate elongation values for different
shows the tensile strength values for different formulations.
formulations and standard minimum value of the HTV
silicone rubber for high-voltage outdoor application. Standard minimum value of tear strength of HTV
Standard minimum value of tensile strength of HTV silicone rubber used in high-voltage outdoor application
silicone rubber used in high-voltage outdoor application is 13 N/mm. Formulation 1 has the highest tear strength
is 400 N/cm2. Formulation 1 has the highest tensile and tear strength decreased with an increase in the filler
strength and tensile strength decreased with an increase ATH concentration
in the filler ATH concentration.
Figure 4 shows the ultimate elongation values for
different formulations and standard minimum value of
the HTV silicone rubber for high-voltage outdoor
application. Standard minimum value of tear strength of
HTV silicone rubber used in high-voltage outdoor
application is 150%. Formulation 1 has the highest
elongation and elongation decreased with an increase in
the filler ATH concentration.
Tear Strength. Figure 5 shows the tear strength values
for different formulations and standard minimum value
of the HTV silicone rubber for high-voltage outdoor
application.
Fig. 5. Tear strength values for different formulations.
 Bhagyashree, Shivabasappa, Raavichandran and Kumar 76

a. Surface and volume resistivity

Fig. 7. Volume resistivity values for different

formulations.

Fig. 6. Surface resistivity values for different

formulations.

Figure 6 shows the surface resistivity values for

different formulations and standard minimum value
of HTV silicone rubber for high-voltage outdoor
application. Standard minimum value of tear strength
of HTV silicone rubber used in high-voltage outdoor
application is 100TΩcm2.
Figure 7 shows the volume resistivity values for
different formulations and standard minimum value
of HTV silicone rubber for high-voltage outdoor
application. Standard minimum value of tear strength
of HTV silicone rubber used in high-voltage outdoor
application is 100 TΩ/cm.
Resistance to tracking and erosion Fig. 8. Arc resistance values for different
• Formulation 1 rubber compound without ATH formulations.
failed to withstand the applied voltage of 4.5kV Figure 8 shows arc resistance of rubber compound
for six hours. The specimen eroded completely with different concentrations of filler ATH. Arc
within 3 hours. resistance of the cured rubber compound increased
• Formulation-2 rubber compound with 40phr with increasing concentration of filler ATH.
ATH withstood the applied voltage of 4.5kV for Dielectric constant
six hours. Erosion was observed in the five test Figure 9 shows dielectric constant of rubber
specimen. compound with different concentrations of filler
• Formulation-3 rubber compound with 50phr ATH. Dielectric constant of the cured rubber
ATH withstood the applied voltage of 4.5kV for compound increased with increasing concentration of
six hours. There was no erosion observed in the filler ATH.
five test specimen. Loss and recovery of hydrophobicity
• Formulation-4 rubber compound with 60phr All the samples followed the criteria as shown the
ATH withstood the applied voltage of 4.5kV for figure 10. Hydrophobicity is classified into 7 classes
six hours. There was no erosion observed in the HC1 to HC6. HC1 is a completely hydrophobic
five test specimen. surface and HC6 is a completely hydrophilic surface.
Arc resistance After corona generation on the sample, the surface
became hydrophilic (Classified as HC6) and the
surface regained hydrophobicity (Classified as HC2)
within 48 hours.
 Bhagyashree, Shivabasappa, Raavichandran and Kumar 77

Fig. 9. Dielectric constant values for different formulations.

Fig. 10: Criteria for hydrophobicity classification.

CONCLUSIONS addition of filler ATH to the silicone rubber improves

the resistance to tracking and erosion.
From the results obtained for HTV silicone rubber with
HTV Silicone rubber IS40A and IS60A are not used as
different concentration of filler ATH it is concluded
housing material for the high voltage applications in
that formulation-3, silicone rubber with 50phr ATH was
composite insulators. Since IS40A has low values for
considered the optimal housing material for high
physical properties and high values for mechanical
voltage applications in composite insulators. 50phr
properties as compared to standard values and also
ATH was considered as the optimum concentration for
there is no resistance for tracking and erosion. Although
the HTV silicone rubber compound. Physical properties
IS60A can withstand applied voltage and no erosion
hardness (Shore-A) and specific gravity increased with
and good electrical properties it cannot be used for high
increasing concentration of filler ATH. Mechanical
voltage applications since it has high values for
properties tensile strength, tear strength and ultimate
physical properties and low values for mechanical
elongation decreased with increasing concentration of
properties as compared to standard values. IS50A meets
filler ATH. Electrical properties such as arc resistance
all the specified requirements as mentioned in the table
and dielectric constant increased with increasing
1, therefore it can be considered as good housing
concentration of filler ATH. Surface and volume
material for high voltage applications.
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