Corrosion Mechanisms and Fault Classification of ACSR Cables in Coastal High-Salinity Zones

Investigating the strand-breakage mechanisms and damage classification of Aluminum Conductor Steel-Reinforced (ACSR) cables in coastal high-salinity zones is critical for enhancing grid reliability and ensuring transmission safety. This study employs a multi-scale methodology to systematically analyze the corrosion-induced strand degradation dynamics of ACSR cables in high-salinity coastal environments. A computational framework based on the finite element method (FEM) is developed to establish a quantitative classification standard for corrosion-related cable faults. First, field samples of corrosion-resistant S-LGL-240/40 ACSR cables were characterized using scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS). These analyses revealed macro/micro-scale morphological features and corrosion product compositions, demonstrating that strand failure arises from synergistic effects of electrochemical corrosion and mechanical stress. Second, a multi-physics coupled model was implemented in ABAQUS to simulate corrosion pits and cross-sectional defects. The model quantifies corrosion severity, strand damage progression, and their impacts on ultimate tensile strength, enabling data-driven fault classification. The findings provide a validated framework for long-term reliability assessment of power transmission systems operating in corrosive coastal environments.