What primary factors contribute to electrical cable failures, and how do material degradation and environmental mismatches specifically impact performance?

Cable failures stem from interconnected degradation mechanisms and environmental incompatibilities. Material aging—accelerated by operation outside design parameters—causes insulation and sheath embrittlement, creating cracks that expose conductors and heighten short-circuit risks. This thermal degradation pathway directly reduces service life, particularly in cables subjected to temperature extremes beyond their rated thresholds.

Environmental mismatches exacerbate failures: insufficient mechanical toughness leaves cables vulnerable to abrasion in industrial settings, while inadequate chemical resistance allows ambient substances to compromise structural integrity. Installation damage further compromises integrity, with sheath degradation from heat, cold, or weathering eliminating critical protection for insulated cores. Moisture ingress compounds these issues, inducing copper conductor corrosion and internal short circuits that cascade into system-wide failures. Together, these factors transform predictable wear into catastrophic performance loss, underscoring the importance of material selection, environmental compatibility, and handling protocols in cable longevity.