Influence of Shear-Induced Pre-Crosslinking on the Mechanical and Dielectric Properties of Crosslinked Polyethylene Cable Insulation.

Crosslinked polyethylene (XLPE) is a widely used cable insulation material for power cables at various voltage levels, offering excellent electrical, mechanical, and thermal stability. However, during the continuous extrusion moulding process, prolonged shear action and localized temperature accumulation can easily induce premature crosslinking. This leads to a decline in melt rheological properties and reduced processing stability, as well as having an adverse effect on the microstructure and overall performance of the formed insulation layer. This study systematically investigated the impact of shear-induced pre-crosslinking on the mechanical properties and dielectric characteristics of XLPE cable insulation materials through experimental testing methods. The experimental results demonstrate that, while premature crosslinking has a minimal effect on mechanical properties, it significantly deteriorates dielectric performance, as evidenced by increased conduction current, reduced breakdown strength, and compromised microstructural integrity. These findings suggest that, to improve the quality and reliability of XLPE cable production, engineering designs should prioritize controlling the pre-crosslinking process to ensure stable dielectric performance.