Investigation into the overcurrent failure and combustion characteristics of copper‐clad aluminum conductors

Abstract Electrical fires perennially rank first in fire occurrence types, with conductor overcurrent being one of the main inducements. This topic draws significant attention from scientific researchers and fire investigators. To understand the overcurrent fault and combustion characteristics of copper‐clad aluminum conductors, this paper examines 2.5 mm 2 copper‐clad aluminum conductors that meet national standards, investigating morphological changes, temperature variations in the core and insulation layer, and flame propagation patterns under overcurrent conditions. Experiments using an electrical fault simulation device were conducted to study overcurrent failures of copper‐clad aluminum conductors under 52.5–105 A conditions. The results indicate that when the current exceeds 67.5 A, the conductor undergoes a series of changes during energization, including smoking, expanding, carbonizing, burning, and breaking; at 52.5 A, the insulation layer reaches thermal equilibrium at 150 s without combustion; for currents between 60–67.5 A, wire core temperature variations can be divided into three stages; at 75 A, the insulation layer reaches thermal equilibrium 10s before breaking; currents above 82.5 A see a sharp increase in temperature in both the core and insulation layer before the conductor breaks; above 97.5 A, the conductor first breaks and then burns. The research results have significant theoretical value in improving the scientific rigor of fire accident investigations and forensic evidence examinations.