Spark Gap Research Articles

Beaware of Intracardiac Potentials Induced by Intravascular Lithotripsy.

Intravascular lithotripsy (IVL), that generates shockwaves through spark gap discharge between emitters, has been increasingly used to treat severely calcified coronary artery lesions. However, there is a question as to whether IVL has no electrical effects on endocardial tissues or cardiac implantable devices (CIEDs). The aim of this study was to investigate the effects of IVL-induced intracardiac potentials on cardiac electrophysiology and CIEDs. Specifically, we examined how spark gap discharge of IVL influence myocardial electrical activity and the sensing function of CIEDs. We conducted a preliminary in vitro experiment using an IVL and a pacemaker placed in a saline-filled container, where we observed that the pacemaker did indeed detect the discharge of IVL, leading to pacing inhibition. Then, 13 patients undergoing PCI with IVL were investigated with real-time monitoring of in vivo intracardiac electrogram (EGM) synchronized with body surface ECG, with an external temporary pacing lead placed in the right ventricle. Similar to the above experiment, we found that IVL pulses were indeed detected on the EGM and sensed by the temporary pacemaker. Of the 287 IVL pulses outside the range of absolute refractory period, 59 (20.6%) captured the ventricle, while the remaining 228 (79.4%) did not elicit any electrical myocardial activity. Our observations indicate concerns about the use of IVL: the risk of inducing fatal arrhythmia and the occurrence of cardiac arrest or bradycardia in the CIED-dependent patients. IVL users should be aware of the potential risk of such events.

Study on a compact pulse forming line-Marx type high voltage pulse generator.

High power pulse generators are moving in the direction of compact, solid-state, and stable working in a relatively long time. In this paper, a compact pulse forming line-Marx type high power pulse generator, based on a ceramic pulse forming line and a spark gap switch with carbide modified graphite electrodes, is studied numerically and experimentally. Specifically, a ceramic based pulse forming line with high relative permittivity was used to achieve long pulse duration in a limited dimension. A spark gap switch with carbide modified graphite electrodes was proposed to decrease the erosion of the electrodes, which can efficiently prolong the lifetime of the device. The generator was built. With a charging voltage of 34kV approximately, pulses with peak current over 2.56kA and a duration of about 86ns were obtained on a matched dummy load of 50Ω. The dimensions of the generator are 360 × 280 × 300mm3. The device can continue working over 6000 pulses with a repetitive rate of 10Hz, which meets potential applications, including plasma science research.

OPTIMIZATION OF A NONCONVENTIONAL MACHINING PROCESS USING MULTI-CRITERIA SELECTION METHODS

Determining the optimal parameters for a process technology requires a full analysis of all the principles and factors that influence it. Nonconventional technologies are more and more present in modern manufacturing processes, so determining the values of the technological and economic parameters is vital. In this paper, multi-criteria methods (ELECTRE, TOPSIS) were used to determine the importance of the criteria and to establish the best combination of parameters (discharge time, off time, average lateral spark gap, lateral roughness, frontal roughness, velocity of erosion) in an electrical discharge machining process with massive electrode for C120 steel at 85V voltage. The dimensions of the depressions in a steel piece depending on the energy or duration of the pulses, and the influence of the moving speed of the semi-finished product on productivity can be also determined. Various multi-criteria decision-making methods are available to help the designers in choosing the decisive course of actions. In the discrete form of multi-criteria decision-making problems, the work flow is confronted with a decision-matrix formed from the information of some alternatives on different criteria. A software application was created that allows the user to enter only the desired parameters and the criteria that must be strictly respected, and the program will choose in a very short time the optimal combination of the available values.

Research on Structural Parameter Design of High Voltage Plane Switch

Abstract In order to determine the structural parameters of the three electrodes of the high-voltage plane switch, the effects of the main electrode gap distance, trigger electrode width, main electrode radius, electrode thickness and other structural parameters on the static breakdown voltage (SBV) of the high-voltage plane switch were obtained by simulation calculation. The optimized structure parameters of the planar switch are obtained, including primary electrode gap 2.0mm, trigger electrode width 1.2mm, trigger electrode in the center of the two main electrodes, and electrode thickness 4 μ m. The performance of the designed high-voltage planar switch is basically consistent with that of the spark gap switch.

A Review on The Nitrogen Laser

Abstract: A nitrogen laser is a type of gas laser that uses molecular nitrogen as its gain medium to operate in the ultraviolet (UV) spectrum. First created in 1963, nitrogen lasers were first put to use in commerce in 1972. A nitrogen laser is a type of gas laser that uses molecular nitrogen as its gain medium to operate in the ultraviolet (UV) spectrum. First created in 1963, nitrogen lasers were first put to use in commerce in 1972.Applications for nitrogen lasers can be found in physics, chemistry, and medical research. The principle of operation for nitrogen lasers is a quick electrical discharge through nitrogen gas. Liquid nitrogen or a gas cylinder might be used to supply the nitrogen gas. The UV-wavelength laser light has a short pulse width and a high intensity. The principle of operation for nitrogen lasers is a rapid electrical discharge via nitrogen gas. Liquid nitrogen or a gas cylinder might be used to supply the nitrogen gas. The laser light has a short pulse width, high intensity, and is released into the ultraviolet spectrum. Electricity is used by the nitrogen laser to excite the nitrogen. The electrons in the laser strike the nitrogen atoms in the air when an electric spark passes through a spark gap, stimulating them into a metastable condition. A photon with a wavelength of 337 nm causes stimulated emission and the creation of a laser state in the excited nitrogen atoms. Electricity is used by the nitrogen laser to excite the nitrogen. The nitrogen atoms in the air are excited into a metastable condition when an electric spark passes through a spark gap in the laser. A photon with a wavelength of 337 nm causes stimulated emission and the creation of a laser state in the excited nitrogen atoms. [22]

EDM SURFACE ANALYSIS OF MOSI2–SIC INTERMETALLIC CERAMIC COMPOSITE WITH ENHANCED FORM AND ORIENTATION TOLERANCES

Electrical discharge machining (EDM) was performed on a copper electrode and the implications of changing factors such as current, pulse on time, pulse-off time, spark gap voltage and speed have been investigated in this research. The process used an intermetallic MoSi2–SiC ceramic composite. Multiple performance characteristics, including material removal rate, electrode degradation rate and surface roughness, run out, radial overcut, circularity, cylindricity and perpendicularity were considered when optimizing these parameters using the Taguchi-based [Formula: see text]Orthogonal Array with Design of Experiments (DoE). For this purpose, techniques such as analysis of variance (ANOVA), Response Surface Methodologies (RSM) and graphical analysis were utilized. The outcomes revealed that geometric tolerances were decreased as a consequence of significant improvements in the rates of material removal, tool degradation, form tolerance, and orientation tolerance. The optimal machining settings for producing high-quality holes and electrodes in the conductive MoSi2–SiC composite were determined by scanning electron microscopy (SEM) testing the anomalies of the machined composite for various holes of trials. The experimental results suggest that the precision, presence of microvoids and surface roughness of the copper electrode can be enhanced through selecting an appropriate optimal combination.

Machining performance, economic and environmental analyses and multi-criteria optimization of electric discharge machining for SS310 alloy

With the expansion of the manufacturing sector, it has become crucial to incorporate sustainable production methods in order to remain competitive in the market. This study focuses on addressing the needs of the manufacturing industry by conducting a sustainability analysis of electric discharge machining for SS310 alloy. The analysis explores the impact of various electrode materials, for instance, copper and brass, as well as different machining variables, including discharge current (I = 4–12 A), spark gap (SG = 6–12 mu), pulse duration (Pon = 15–45 μs), and duty cycle (DC = 75–85%) using Taguchi method. The objective is to optimize the machining performance measures, which includes material removal rate (MRR), surface roughness (Ra), electrode wear (EW), and energy consumption (EC). In addition, the economic analysis of the machining process takes into account factors such as energy cost, dielectric consumption cost, EW cost, labor cost, and machine depreciation cost for both types of electrodes. Furthermore, the study investigates the carbon emissions resulting from EC, dielectric consumption, and EW to assess the environmental impact of the machining process. Multi-criteria decision-making approach is employed to assess the sustainability of the machining process by taking into account several performance, cost and environmental factors simultaneously. From empirical analysis, it has been observed that the copper electrode outperformed the brass electrode in terms of MRR (2.67 mm3/min), Ra (3.36 µm), EW (0.272 g), and EC (145.08 kJ) due to its superior electrical and thermal characteristics. In the cost analysis, copper offered lower costs for EC (2.02 PKR) attributed to its higher electrical conductivity while higher costs in terms of EW (5.5 PKR) and dielectric consumption (5.2 PKR) than brass. However, the analysis of labor and machine depreciation costs revealed that the application of copper electrode results in lower costs (80.1 and 99.3 PKR, respectively) than the brass electrode primarily due to its shorter machining time. The analysis of the environmental impact showed that the utilization of a copper electrode leads to reduced carbon emissions of 9.8 g CO2 due to its lower EC during the machining process. However, the copper electrode results in higher emissions from EW (5.07 g CO2) and dielectric consumption (54.58 g CO2) compared to the brass electrode. Based on the multi-criteria decision-making using the composite desirability function approach, it is evident that the copper electrode exhibits superior performance in terms of MRR, Ra, and total machining cost. Conversely, the brass electrode demonstrates better performance in terms of overall carbon emissions.

Gas jet structure effects on fuel concentrations and flames in a hydrogen low-pressure direct-injection spark-ignition engine

This study aims to find the impact of the nozzle shape of a side-mounted, 3.5-MPa pintle injector on hydrogen concentration and flame development in a low-pressure direct-injection spark ignition (H2LPDI) engine. To this end, endoscopic high-speed imaging of gas jet laser shadowgraph and flames as well as spark-induced breakdown-spectroscopy (SIBS) method are applied to one of the inline four cylinders of H2LPDI engine. Two engines with endoscopic access are used: one motored engine for high-speed laser shadowgraph imaging of gas jet development and the other combustion engine for SIBS-based spark gap [Formula: see text] measurements and high-speed hydrogen flame imaging. The gas jet visualisation showed that a nozzle with a narrower jet spreading angle leads to more turbulent jet boundaries and the jet axis being directed more towards the piston. Due to higher axial momentum, the narrower spreading angle nozzle also caused enhanced jet penetration across the in-cylinder tumble flow. This jet development pattern resulted in locally leaner hydrogen mixtures near the centrally mounted spark plug at the time of ignition, evidenced by a higher difference between spark gap λ and global λ. As a result, the flame size was measured smaller at any fixed combustion stage. For both nozzle types, the injection timing was also varied between 150 and 120 °CA bTDC but there was no significant difference measured in spark gap [Formula: see text] and flame size compared to that associated with the nozzle type.

Interference Characteristics of Electromagnetic Transient Overvoltage on Secondary Equipment of UHV Fixed Series Capacitors

This manuscript addresses the issue of electromagnetic radiation interference experienced by secondary equipment in ultra-high voltage (UHV) fixed series capacitors (FSCs) under electromagnetic transient overvoltage conditions, which cannot be easily determined. To tackle this, a simulation and analysis method for the electromagnetic interference characteristics of secondary equipment is proposed. First, a primary system simulation model of UHV FSC is established, including modeling the platform’s multi-conductor system. The electromagnetic transient overvoltage signals between the low-voltage busbar and the high-potential platform are then simulated and analyzed under two conditions: spark gap triggering and disconnector operation. Next, a finite element model of secondary equipment is created to simulate and analyze the electric field distribution of different materials in the area of the measuring box. The shielding effectiveness of the measuring box is calculated using the overvoltage signals at the measuring box location as excitation. This method allows for the simulation of the electric field distribution in the measuring box area for different materials and calculates the shielding efficiency of the measuring box. It effectively simulates the complex electromagnetic environment of secondary equipment, assesses the electromagnetic shielding efficiency of the measuring box, and provides a theoretical basis for analyzing and improving the anti-interference characteristics of the measuring box.

Estimating the minimum ignition energy of spark-ignited fuel/air mixtures: preliminary steps towards a novel modelling approach

Abstract In spark-ignition (SI) engines, the achievement of a fast combustion with low cycle-to-cycle variation is highly dependent on the successful initiation of a flame kernel from the spark plug. Its growth can be sped up by increasing the electrical energy supply, but at the cost of higher plug wear, whereas too little energy may result in an ignition failure. Therefore, knowledge of the minimum ignition energy (MIE) of a fuel/air mixture is of key importance to guarantee a proper combustion process at minimal cost. To model the MIE several approaches have been proposed in literature, primarily derived from the experiments conducted by Lewis and Von Elbe and their resulting theory of quenching distances. However, these approaches appear in conflict with more recent experimental outcomes, and the impact of the ignition device is neglected. This work proposes a novel approach for modelling the MIE, which is based on a flame kernel expansion model recently proposed in another paper. In this approach, the proposed model, which has general validity, is specialized to the particular case of the estimation of the MIE, supplied via an electrical breakdown. A model advancement is also included that consists in the quantification, albeit at a preliminary level, of the impact of different gap distances and spark plug quenching effects on the flame kernel development. The results are validated against literature models and experimental data for two fuels, propane and hydrogen, and multiple equivalence ratios. In contrast with the noticeable MIE overestimation of literature models, for propane the proposed approach leads to better results compared to the experiments. Instead, for hydrogen a tendency towards a MIE underestimation is observed, especially for lean mixtures. The model is also tested for SI-engine-relevant conditions, showing satisfactory overall trends. The key source of error seems related to the very complex kernel-electrode interaction, the modelling of which will be improved in future developments.

Impact of overvoltage on the mode transition of the spark gap switch: from edge breakdown to stochastic breakdown

Abstract Spark gap switch (SGS) is a fundamental but critical component for large-scale pulsed power devices, whose reliable operation is significantly affected by the breakdown characteristics of SGS. It is observed experimentally that, with the increase of overvoltage, the bridging position of the spark channel transits from edge to stochastic center. In this work, the influence of overvoltage on the breakdown process of a parallel-plate SGS with low geometric distortion of static electric field (<13%) between an atmospheric-pressure air gap of 5 mm is investigated by particle-in-cell/Monte Carlo collision simulation. It is found that, under a low overvoltage (ratio of applied voltage U a to static breakdown voltage U 0, U a/U 0 = 1.5), the streamers at the edge first bridge the gap before that in the central region, due to the field enhancement induced by the electrode curvature. Under higher overvoltage (U a/U 0 = 3), the synchronicity between streamers initiating from the center and those from the edge is greatly improved during the inception stage. After the streamers pass the middle of the gap, the field enhancement at the streamer front is more intensified and promotes the generation of fast electrons. These fast electrons rapidly magnify the difference among the propagating streamers by providing abundant seed electrons ahead of the discharge channel, which leads to the randomness of the bridging position. The results in this work demonstrate the relationship between overvoltage and streamer dynamics, which is beneficial for the performance improvement of SGS.

Methodology for measuring the energy characteristics of two-electrode gas discharge plasma switches in the picosecond range using the reflectometry method

This research proposes a new technique for measuring the energy characteristics (losses of energy in the spark gap, related to light radiation, ionization, excitation, and heating of the working gas during the development of plasma; discharge power) of two-electrode gas dischargers in the subnanosecond range. The work examines the voltage waveforms across the discharge gas gap and the discharge current waveform obtained by the reflectometry method in the subnanosecond range. To do this, the traditional technique for measuring such characteristics was modified. This allows us to restore the back edge of the voltage pulse across the discharge gap at the breakdown delay and the breakdown stages, which is usually lost in the subnanosecond range when measuring such waveforms. For modification, calculated data on the ionization frequency were used. This allows us to replace the plasma of the discharge gap with a constant resistor in those sections of the voltage waveform where the characteristic ionization time is more than an order of magnitude longer than the duration of the voltage pulse applied to the gap. The waveforms of the voltage across the discharge gap and the discharge current obtained in this way allowed us to calculate the power dynamics and total energy introduced into the gas discharge plasma. These parameters are important both for calculating the efficiency of gas switches and for other applications of gas discharge plasma, in particular laser pumping.

The structural characteristics of nano-copper thin films produced via laser-assisted electric wire explosion process

Abstract Due to the wide range of important applications, the metal and metal oxide nanoparticles have increasing demand, so that many methods and technologies attempted to produce it. The Electric Wire Explosion (EWE) method is the most established method to produce nanometals and metal oxides in the form of either powders or thin films. In this study, copper and copper oxide films were prepared via electric wire explosion method with a developed laser igniting spark gap switch. The Cu thin films were prepared at different explosion voltages (4, 5 and 7kV) and then their structural properties were studied. The results show that the produced copper/copper oxides nanoparticles of thin films increased as the exploding voltage increased. The XRD test shows that the films crystallite size increased as the exploding voltage increased. FE-scanning electron microscope (FE-SEM) images, are shows the decrease of grain size of thin films as the explosion voltage increase.

Testing the operation of protection devices against parallel arc breakdown and spark gaps in the event of a ground fault

Testing the operation of protection devices against parallel arc breakdown and spark gaps in the event of a ground faultTHE PURPOSE. Develop a laboratory rig for testing parallel arc fault and spark gap protection devices for tripping in the event of a ground fault. Conduct laboratory rig tests with subsequent development of requirements for the use of parallel arc fault and spark gap protection devices for tripping in the event of a ground fault.METHODS. Mathematical and statistical methods of analysis were used to achieve the stated objective. Laboratory tests of parallel arc fault and spark gap protection devices for different network parameters for correct tripping in the event of a ground fault.RESULTS. Laboratory tests of parallel arc fault and spark gap protection devices for correct tripping in the event of a ground fault were conducted with different network parameters. The oscilloscope recorded the shape of the voltage and current curve in the event of a ground fault and the tripping time of the devices. The tested devices demonstrated the ability to recognize and disconnect a ground fault. The tripping time of the devices varies, however, does not exceed the established requirements.CONCLUSION. A laboratory stand has been developed for testing parallel arc breakdown and spark gap protection devices for operation during a ground fault. This stand makes it possible to test devices for adequate operation during a ground fault with subsequent certification. The tests conducted demonstrate the need to develop mandatory requirements for the device to standardize their operating algorithm. Therefore, the use of this protection device can contribute to safer operation of low-voltage electrical networks by preventing emergency situations and reducing the risk of fires. This is an important technical aspect for improving the reliability and safety of power supply.

A Computer Model of a Marx Generator Charging a Coaxial Switched Wave Oscillator

The paper describes an axisymmetric Finite-Difference Time-Domain computer model of a coaxial Switched Wave Oscillator integrated with a dipole antenna. The model analyzes the operation of a realistic circuit model of a multistage Marx generator that charges the oscillator to a high voltage. The initial field distribution is calculated with an electrostatic finite-difference method solver to speed up the time-domain analysis. The work presents the results of our circuit model of a Marx generator’s simulations of the charging phase, followed by the results from the discharge phase, using our axisymmetric Finite-Difference Time-Domain model. Our work describes new and fast numerical solvers that can observe the operation of Switched Wave Oscillator systems (also considering the connected antenna). The codes could be used in the process of designing such a system. Advanced boundary conditions modeling the spark gap and oscillator’s excitation set our work apart from the other attempts in the literature.

Investigation of machining performance of waspaloy using copper-graphite composite electrodes in electric discharge machining

Abstract This study endeavoured to investigate the machining of Waspaloy using Electric Discharge Machining (EDM), utilizing copper-graphite composites as the tool material. Given the limited existing research on machining Waspaloy with composite tools, this study aims to address this gap by employing a copper-graphite composite tool. In this work, pure copper electrode and three composite electrodes with varying graphite percentages in copper, viz. copper containing 5%, 10%, and 15% graphite (CuGr-5, CuGr-10, and CuGr-15), are utilized for experimentation. Composite electrodes are fabricated by the stir-casting process. The scanning electron microscope reveals that the graphite specks are homogeneously disseminated over the matrix material. The Taguchi mixed orthogonal array was used for developing experimental runs. By varying the current, polarity, pulse on and off times, tool materials, and gap, machining performance was measured in terms of Material Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (Ra). It was observed that CuGr-5 provides an enhancement in MRR due to the improved electric conductivity, bridging effect, and increased energy concentration at the spark gap. Diverse characteristics witnessed on the surface morphology include black dots, globules, remelted layers, micro-cracks, and scratches. When machined with a CuGr5 electrode, the surface quality improved owing to the completed flushing and uniform distribution of generated heat as confirmed through worn surface morphology. The parameters were optimized utilizing the PROMETHEE optimization technique; it was found that the CuGr-5 electrode with the assessment value 0.02458 was optimal for machining of Waspaloy.

Development of a Miniaturized 2-Joule Pulsed Plasma Source Based on Plasma Focus Technology: Applications in Extreme Condition Materials and Nanosatellite Orientation.

Plasma focus devices represent a class of hot and dense plasma sources that serve a dual role in fundamental plasma research and practical applications. These devices allow the observation of various phenomena, including the z-pinch effect, nuclear fusion reactions, plasma filaments, bursts, shocks, jets, X-rays, neutron pulses, ions, and electron beams. In recent years, considerable efforts have been directed toward miniaturizing plasma focus devices, driven by the pursuit of both basic studies and technological advancements. In this paper, we present the design and construction of a compact, portable pulsed plasma source based on plasma focus technology, operating at the ~2-4 Joule energy range for versatile applications (PF-2J: 120 nF capacitance, 6-9 kV charging voltage, 40 nH inductance, 2.16-4.86 J stored energy, and 10-15 kA maximum current at short circuit). The components of the device, including capacitors, spark gaps, discharge chambers, and power supplies, are transportable within hand luggage. The electrical characteristics of the discharge were thoroughly characterized using voltage and current derivative monitoring techniques. A peak current of 15 kiloamperes was achieved within 110 nanoseconds in a short-circuit configuration at a 9 kV charging voltage. Plasma dynamics were captured through optical refractive diagnostics employing a pulsed Nd-YAG laser with a 170-picosecond pulse duration. Clear evidence of the z-pinch effect was observed during discharges in a deuterium atmosphere at 4 millibars and 6 kilovolts. The measured pinch length and radius were approximately 0.8 mm and less than 100 μm, respectively. Additionally, we explore the potential applications of this compact pulsed plasma source. These include its use as a plasma shock irradiation device for analyzing materials intended for the first wall of nuclear fusion reactors, its capability in material film deposition, and its utility as an educational tool in experimental plasma physics. We also show its potential as a pulsed plasma thruster for nanosatellites, showcasing the advantages of miniaturized plasma focus technology.

Effective lifetime of Ni laser induced fluorescence excited at 336.9 nm during spark plug discharge

In this study, the laser induced fluorescence lifetime of Ni atoms in ambient air with presence of a plasma discharge was measured for the first time. Free Ni atoms were generated in air at a pressure of 1 bar by spark plug discharges driven by an inductive coil. The Ni atoms were excited at the 336.957 nm absorption line by a 336.96 nm, 90 ps laser pulse and the resulting temporally resolved decaying fluorescence signals were captured by a PMT. An effective fluorescence lifetime of about 1.1 ns was observed for the fluorescence signal within a 7.4 nm detection window centered at 345 nm. Further analysis also revealed that the lifetime of the transition showed statistically insignificant change throughout the duration of the discharge. The peak intensity of the fluorescence signal was found to be proportional to the integrated signal intensities. This in turn suggests that the integrated fluorescence signals in the aforementioned spectral region are proportional to the population density of ground state Ni atoms in the detection volume. The number density of free Ni atoms in the spark gap was measured over time during the plasma discharge, showing an accumulating trend in the beginning phase of the discharge followed by a slow decrease until the termination.

Self-breakdown statistics of a high-pressure spark gap with a microarray graphite cathode.

Comparative measurements with high-pressure spark gaps (gas pressure: 0.2-0.9 MPa nitrogen, gap spacing 5mm) are presented, one with a regular Bruce-profile polished graphite cathode (diameter 25mm, thickness 8mm) and the other with a microarray graphite cathode of equal dimensions. By microstructuring, a V-type graphite microarray is created by purpose-developed laser treatment of a plane graphite electrode. The microarray graphite cathode brings more initial plasma and then produces more initial electrons. It is beneficial for electron emission, which improves the stability of the switch breakdown. The experimental results are achieved at a gas pressure of 0.9 MPa and a 200-kV voltage pulse applied to the switch. With these parameters, the mean breakdown voltage is 91.7kV, the minimum is 91.4kV, and the mean relative standard deviation in breakdown voltage of the first 100 shots is 0.4%. Compared to a plane graphite cathode, the mean breakdown voltage is about 10% lower, and the mean relative standard deviation is reduced by more than 90%. The main result can be stated that microarray graphite cathodes are a suitable choice as electrodes for low-jitter high-pressure spark gaps.

Performance evaluation in die-sinking EDM of polygonal micro cavities over EN-24 alloy steel using cylindrical electrode and polygon cycle approach

The integration of advanced Electrical Discharge Machining (EDM) technology, incorporating short and electronically pulsed discharges with precise circular electrode movements, has enabled the production of intricate 3D microstructures and cavities. This paper aims to investigate the machining performance of polygonal cavities—triangular, square, pentagon, and hexagon—fabricated on steel samples using a 400 µm cylindrical copper electrode within the polygon cycle approach of EDM. Experimental investigations were conducted to assess shape error, tool wear rate, recast layer formation, and elemental characterization. Various discharge patterns and side discharges were examined to understand their effects on spark gap uniformity, tool deflection, and discharge stability. The results revealed non-uniform spark gaps, tool deflection, and corner rounding due to varying discharge patterns and side discharges. Tool wear rate was found to be directly related to polygon complexity, with higher-order polygons leading to increased wear due to extended machining durations and heat accumulation. The maximum tool wear of 7.69 × 104 µm3/s occurred in case of hexagonal cavities while in case of triangular cavities, the tool wear rate was minimum having value of 5.77 × 104 µm3/s. Scanning Electron Microscopy (SEM) examinations showed the presence of recast layers and micro-cracks, particularly in cavities with higher shape complexities. Energy Dispersive X-ray Spectroscopy (EDS) analysis identified copper deposition, local material evaporation, and foreign element accumulation on the cavity surfaces. This study provides insights into the machining performance of polygonal cavities in EDM processes. The findings underscore the influence of discharge patterns, polygon complexity, and material interactions on tool wear, surface quality, and microstructure integrity. Understanding these factors can inform optimization strategies for EDM processes, leading to enhanced precision and efficiency in microstructure fabrication.