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, Non-member (Nonlinear Systems) Zinc Oxide (ZnO) elements which have non-linear current-voltage characteristic have a number of failure mechanisms when ZnO elements absorb surge energies. Failure mode at the edge of the metal sprayed electrode are among the most common failure mechanisms at high current surges. Such failures take the form of a melt pinhole from the electrode edge to the counter electrode or the side surface of the disk element. As a result of the measurement of the resistively-temperature characteristic at high current region and the computation of the electric and thermal field distribution, it was made clear that the failure at the electrode edge was caused by the partial melting by the current concentration and the local thermal runaway at the electrode edge. Moreover, the current concentration was reduced by the decreasing of the distance between the electrode edge and the sintered ZnO body.We developed the metal sprayed electrode manufacturing process which could control the edge margin. And using this electrode process, the energy absorption capability of the ZnO elements was improved largely by reducing the current concentration at the electrode edge.

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