Synthesis, Characterization and Partial Discharge Testing of SiC/Al2O3 Composite /

Abstract

High-performance dielectric materials are crucial in electric vehicle (EV) power modules, where dependable insulation and thermal control are vital for system efficiency and safety. This work examines the dielectric characteristics of silicon carbide (SiC)-reinforced alumina (Al2O3) composites to improve their applicability in high-voltage insulation. The composites were synthesized via solid-state techniques at 1600 °C in an inert environment, with aluminum content varied at 16%, 25%, 33%, and 40% to adjust the proportions of SiC and Al2O3. The resultant samples were assessed for microstructural, compositional, and electrical properties using scanning electron microscopy (SEM) with energy-dispersive spectroscopy (EDS), X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), and partial discharge (PD) measurements. Microstructural investigation revealed a reduction in Al2O3 content corresponding to diminished aluminum content, hence affirming an elevated SiC concentration in the composite. The samples with elevated SiC concentrations demonstrated enhanced resistance to partial discharge, underscoring their capability to endure electrical stress in high-voltage settings. This study shifts the attention from the mechanical and thermal properties of SiC/Al2O3 composites to the crucial aspect of dielectric behavior by systematically altering aluminum concentration to elucidate its impact on insulation performance. Our findings provide significant insights into the structure property connections of SiC/Al2O3 composites, enhancing their applicability as dielectric materials in electric vehicle power systems and other electronic applications necessitating dependable high-voltage insulation.