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Material: High-quality carbon structural steel, commonly 20# steel, 35# steel, or 45# steel (in accordance with GB/T 699 or the corresponding ASTM standard).
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1. Material and Manufacturing Process
- Material: High-quality carbon structural steel, commonly used. 20# Steel 、 35# Steel or 45# Steel (Complies with GB/T 699 or the corresponding ASTM standard.)
- Process: Overall die forging.
- Heat Treatment: Normalizing or Quenching and tempering 。
2. Mechanical Properties
- Strength grade: According to the mechanical load design of insulators, common grades are: 70 kN, 100 kN, 120 kN, 160 kN, 210 kN, 300 kN 。
- Yield strength: ≥335 MPa.
- Tensile strength: ≥510 MPa.
- Elongation: ≥20% (the high ductility of forgings is their core advantage in preventing brittle fracture).
3. Surface Corrosion Protection
- Handling method: Hot-dip galvanizing 。
- Meets the standard: ISO 1461 / ASTM A153 / GB/T 13912.
- Galvanizing quality:
◎ Average thickness: For particles ≥86 μm, the specification shall be increased to 100 μm in accordance with the contract requirements.
◎ Quality Requirements: The zinc coating shall be complete, of uniform thickness, and have a smooth surface, with no zinc nodules, areas of incomplete plating, or black spots.
4. Structure and Connection Dimensions
- Connection standard: Strictly adhere to IEC 60120 、 IEC 60471 or ANSI C29.2 。
- Common interface types:
◎ Ball head/bowl head: Such as levels 16, 20, and 24.
◎ Groove type/Ring type: Common U-shaped or flat-head connections.
◎ Eye-ring type: Commonly used for composite crossarms or specific hardware.
◎ Connection Hole: The dimensions and hardness of the hardware crimping area are precisely controlled to ensure exceptionally high gripping force after crimping onto the core rod, while avoiding damage to the core rod.
5. Quality Control
- Flaw detection: 100% magnetic particle inspection (MPI) or ultrasonic testing (UT) shall be performed to ensure that the hardware is free of forging folds, cracks, and inclusions.
- Accuracy: Tolerance for critical connection features (such as ball-head diameter and socket opening) shall be controlled within ±0.5 mm.
- Appearance: Forging burrs shall be thoroughly removed, and fillet radii shall be smoothly transitioned to prevent corona discharge under high-voltage conditions.
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