Effects of Overload Current on the Ignition and Burning Hazards of Polyethylene-Insulated Wires

To quantitatively elucidate the effects of overload current on the ignition and burning hazards of polyethylene-insulated wires, 2.5 mm² polyethylene-insulated copper wires used commercially were tested in an electrical fire fault simulation system. Experiments were conducted to study the evolution of overloads, ignition, and burning. The entire process, from insulation smoking and ignition to sustained burning and final extinction driven by wire fusing, was recorded using synchronized digital and high-speed imaging. Video-based measurements were used to extract the following: smoking emission duration, ignition time, burning duration, maximum flame height, and segmented flame width. The results show that stable ignition and sustained burning occur when the overload current is greater than or equal to 180 A. As the current increases, ignition occurs earlier, while the smoking stage becomes shorter but exhibits nonmonotonic fluctuations. The burning duration shows a staged response. It first increases, then decreases toward a relatively stable level. This reflects the competition between enhanced Joule heating and accelerated wire melting and fusing. Maximum flame height and segmented flame width vary nonmonotonically with current, and the segmented flame width peaks at 200 A. A multi-indicator fire hazard evaluation framework was established and an entropy-weight TOPSIS method was applied to integrate the quantification and ranking. The overall fire hazard is greatest at 200 A. These findings provide experimental insight into overload-induced ignition and combustion behavior and contribute to a quantitative understanding of fire hazard evolution in overloaded electrical wires.