Coupled Electro-Thermo-Mechanical Model for Damage Prediction in OPGW Cables Under Short-Circuit and Lightning Stresses: Non-Uniform Current Distribution

Optical ground wire (OPGW) cables are subjected to extreme electromagnetic stresses from lightning and short circuits. Existing models have three main limitations: (i) they assume uniform current distribution, (ii) they use constant material properties, and (iii) they do not couple the electromagnetic, thermal, and mechanical domains. This paper proposes a coupled multiphysics model that incorporates non-uniform current distribution with ${\mu }_r$ dependent on the magnetic field, temperature-dependent properties, and differentiated failure criteria. The model was implemented in COMSOL Multiphysics and was validated against experimental short-circuit tests (15–30 kA) conducted at the HPT-Laboratory (FEC). For the lightning scenario (10/350 $\mathsf{\mu }$s impulse), the model predictions were compared with experimental results reported in the literature, showing good agreement in temperature rise and damage patterns. Results show that including a non-uniform current distribution modifies the predicted maximum temperature by 15.8% and shifts its location from the center to the outer aluminum layers. The model reproduces the experimental temperature with an RMSE of <7 °C and a relative error of <8%. A combined failure criterion (thermal + mechanical) predicts strand breakage with 89.2% accuracy, outperforming the purely thermal (72.5%) and mechanical (78.3%) criteria. Specific $I-t$ and $I^{2}t$ curves were generated for two commercial OPGW cable configurations (Manufacturer A and Manufacturer B), with $I^{2}t$ capacities at 500 ms of 128 kA²s and 98 kA²s, respectively. The proposed model provides a useful tool for protection selection and coordination in transmission lines with OPGW cables.