Design of Smooth Aluminum Bonded Sheaths in HV XLPE Cables Based on the Bending Performance Research

In China, recent ablation failures of water-blocking buffer layer occurred in high voltage (HV) cross-linked polyethylene (XLPE) cables with corrugated aluminum sheath have stimulated the product development of cables with smooth aluminum bonded sheath. Despite the many advantages, bending performance is one of the few weaknesses of smooth aluminum bonded sheath. In this paper, a three-dimensional model of a cable with smooth aluminum bonded sheath in a four-point bending test was set up, where the cohesive zone model was applied to simulate the mechanical behavior of the adhesive layer (bonding interface). The influence on the bending performance of the bonded sheath by the thickness of aluminum layer, the parameters of hot melt adhesive, the thickness and material parameters of outer jacket, as well as the cable specification was investigated, together with the stress distribution and damage analysis of the adhesive layer. Based on the research, the material selection and structural design of smooth aluminum bonded sheath were recommended for HV XLPE cables, including an additional requirement for the shear strength of hot melt adhesive besides those already in IEC and IEEE standards. Finally, a 110 kV XLPE cable with smooth aluminum bonded sheath was manufactured and type tested.