Nonlinear properties of ZnO-polymer composites prepared by solution-casting method

► Novel solution-casting technique is suggested to produce low voltage varistors. ► Lower breakdown voltages could be reached by increasing polyaniline content. ► Both nonlinearity of varistors and their mechanical stability have been improved. ► Lifetime of varistors was increased by increasing polyaniline content. ► The varistors could be used many times with low degradation.