Unanticipated Effects of Epoxy Impregnating Transformers
Many Sandia components for military applications are designed for a 20-year life. In order to determine if magnetic components meet that requirement, the parts are subjected to selected destructive tests. This paper reviews the re-design of a power transformer and the tests required to prove-in the re-design. The re-design included replacing the Epon 828/Mica/methylenedianiline (curing agent Z) epoxy encapsulant with a recent Sandia National Laboratory (SNL) developed epoxy encapsulant. The new encapsulant reduces the Environmental Safety and Health (ES and H) hazards. Life testing of this re-designed transformer generated failures; an open secondary winding. An experimental program to determine the cause of the broken wires and an improved design to eliminate the problem was executed. This design weakness was corrected by reverting to the hazardous epoxy system.