Electrical transmission overhead lines use an aluminum conductor in services. However, protection of the aluminum conductor from corrosion has to be considered. Hence, an extensive experimental work was done to prepare the composite coating of the aluminum conductor. Three types of polyurethane composites were fabricated with different fillers (5 wt% carbon and 5 wt% organoclay) and were characterized. The composites were polyurethane/carbon (PC), polyurethane/organoclay (PClay), and polyurethane/carbon/organoclay (PCClay). Thermogravimetry analysis and Fourier transform infrared spectroscopy were conducted to obtain thermal properties and chemical bonding of the composites. To obtain the corrosion resistance, salt spray tests were applied. To obtain hydrophobicity properties, the contact angle between water and the composites was measured. Measurements of composites relative permittivity was conducted to obtain dielectric properties. A water vapor permeability test was conducted to obtain the rate of water/gas vapor discharge. Finally, an adhesion test was conducted to obtain adhesion performance according to the ASTM D3359 standard. Based on characterization, PCClay had better characters to be used as an overhead aluminum coating material followed by PC and PClay.

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Carbon/polyurethane film composite were prepared by adding carbon with different content in polyurethane as a matrix. The materials were characterized by means of thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), Fourier transform infrared spectroscopy (FT-IR), Optical microscope and salt spray test. TGA and DSC results showed decomposition temperature shifted to a lower point and the FT-IR spectra showed chemical reaction of carbon/polyurethane matrix. The corrosion resistance overall decrease with the increasing carbon content.

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