Materials physics and mechanics

RAR RUS 1-11 Institute for Problems in Mechanical Engineering, Russian Academy of Sciences Ermolaeva Yu.V.

St. Petersburg, Russia

Peter the Great St. Petersburg Polytechnic University Krasnitckii S.A.

St.Petersburg, Russia

0000-0003-0727-6352 Institute of Problems of Mechanical Engineering RAS Gutkin M. Yu.

St.Petersburg, Russia

Temperature dependence of linear fracture mechanics parameters in ceramics: a finite element study Parametric finite element simulations are conducted to investigate the steady-state growth of a crack in ceramic material under various temperature conditions. The temperature dependences of elastic moduli and specific surface energy are incorporated to compute the critical fracture parameters such as the crack length, the failure stress and the energy release rate. The finite element modelling is first verified against Griffith’s theory and then implemented to practical case of cracks growing from a pore. It is demonstrated that crack growth can be energetically favorable at elevated temperatures, whereas it can be inhibited at low temperatures. 10.18149/MPM.5362025_1 high-temperature ceramics cracks pores linear fracture mechanics finite element method https://mpm.spbstu.ru/article/2025.111.1/ 1_ermolaeva_et_al.pdf

RAR RUS 12-24 Ioffe Institute Valeeva A.R.

St. Petersburg, Russia

National Research Centre "Kurchatov Institute" -Central Research Institute of Structural Materials "Prometey" Staritsyn M.V.

St. Petersburg, Russia

Ioffe Institute Senkevich S.V.

St.Petersburg, Russia

Ioffe Institute Kaptelov E.Yu.

St.Petersburg, Russia

Ioffe Institute Pronin I.P.

St.Petersburg, Russia

National University of Science and Technology “MISiS” Kiselev D.A.

Moscow, Russia

Peter the Great Saint-Petersburg Polytechnic University Nemov S.A.

St. Petersburg, Russia

Influence of bending deformation in spherulitic films of lead zirconate titanate on the formation of the internal field and self-polarization Experimental studies of the internal field and self-polarization in thin lead zirconate titanate films formed on platinized silicon substrates using a two-stage radio-frequency magnetron sputtering of a ceramic target were conducted. In the first stage, amorphous films were deposited on a cold substrate, and in the second stage, high-temperature annealing was performed, accompanied by crystallization of the perovskite phase and the formation of a spherulitic microstructure. The aging characteristics of these films, associated with the formation of non-uniform mechanical stresses leading to the upward diffusion of oxygen vacancies (the Gorsky effect), were studied. Estimates were made of the diffusion rate of oxygen vacancies, as well as their concentration, necessary for the formation of an internal field in thin films. It was shown that a change in the crystallization (synthesis) temperature of the perovskite phase can lead to a change in the direction of the gradient vector of non-uniform mechanical stresses and the direction of diffusion of oxygen vacancies towards the substrate. 10.18149/MPM.5362025_2 lead zirconate titanate thin films spherulitic microstructure rotational crystals self-polarization internal field bending mechanical deformation Gorsky effect https://mpm.spbstu.ru/article/2025.111.2/ 2_valeeva_et_al.pdf

RAR RUS 25-43 Peter the Great St. Petersburg Polytechnic University Bakkar M.

St. Petersburg, Russia

Peter the Great St. Petersburg Polytechnic University Mhemeed Dbes A.

St. Petersburg, Russia

Institute for Problems in Mechanical Engineering of the Russian Academy of Sciences Avdonyushkin D.V.

St. Petersburg, Russia

Peter the Great St. Petersburg Polytechnic University Semenov Artem

St.Petersburg, Russia

Configurational force distribution during perovskite phase growth in a ferroelectric film The propagation of the interphase boundary during the growth of the perovskite phase in a pyrochlore matrix in thin ferroelectric lead zirconate titanate films on a silicon substrate is studied using the methods of configurational force mechanics. A numerical solution of the boundary value problem of the growth of a perovskite inclusion in an initially pyrochlore film is obtained in axisymmetric and three-dimensional formulations. The growth of cylindrical, conical, and spherical inclusions is considered. The growth of single and multiple regularly and irregularly located inclusions were studied. A comparison of the solutions to the problem in linear-elastic and elastoplastic formulations was made. The dependence of the configurational force on the inclusion size and on the distance from the substrate is obtained. In the modeling, the interphase boundary rate was determined by a power-law dependence on the configurational force. Based on the results of finite-element computations of the spatial and temporal distribution of the configurational force and the evolution equation for the growth rate of the interphase boundary, the gradient of the growth axis angle deviation was determined, correlating with the experimental data obtained from X-ray diffraction analysis and scanning electron microscopy. 10.18149/MPM.5362025_3 lead zirconate-titanate thin films spherulitic microstructure configurational forces stress relaxation finite-element modeling and simulation https://mpm.spbstu.ru/article/2025.111.3/ 3_bakkar_et_al_corrected.pdf

RAR RUS 44-52 Pryazovskyi State Technical University Kargin S.B.

Mariupol, Russia

Peter the Great St. Petersburg Polytechnic University Artiukh V.G.

St. Petersburg, Russia

Peter the Great St. Petersburg Polytechnic University Kitaeva D.A.

St.Petersburg, Russia

Peter the Great St. Petersburg Polytechnic University Korihin N.V.

St. Petersburg, Russia

Peter the Great St. Petersburg Polytechnic University Kruglov A.I.

St. Petersburg, Russia

Development of theoretical basics and experimental verification of progressive methods of graphite oxidation with simultaneous grinding The first attempts of scientifically based analysis of grinding process belong to Rittinger and Kik. Results of theoretical and laboratory studies aimed to obtain finely dispersed graphite for manufacture of technological lubricants are presented. Modern very labor-intensive technology for grinding graphite is shown and its shortcomings are indicated. Theoretical analysis of possibility of changing graphite by progressive method of oxidative milling of graphite with help of hydrogen peroxide is given. Original method of laboratory research on oxidative grinding of graphite has been developed. Presented results of laboratory studies fully confirmed theoretical calculations that makes it possible to simplify process of obtaining colloidal graphite for technological lubricants. This eliminates operation of washing colloidal graphite from decomposition products of chromium mixture and sulfuric acid which takes place in manufacture of OGV lubricant. 10.18149/MPM.5362025_4 graphite grinding acid medium chromium mixture lubricant potassium bichromate ammonia adsorption hydrogen peroxide cation-exchanger https://mpm.spbstu.ru/article/2025.111.4/ 4_kargin_sb_et_al.pdf

RAR RUS 53-62 Mahamaya Government Degree College Kumar Anuj

Sherkot, Bijnor, Uttar Pradesh, India

Swami Vivekananda Srivastava Ragini

Subharti University, Meerut, UP, India

Swami Vivekanand Kumar Amit

Subharti University, Meerut, UP, India

Swami Vivekanand Subharti University Kumar Rajiv

Meerut, UP, India

SRM Institute of Science and Technology Kumar Sarvendra

Delhi NCR Campus Modinagar, UP, India

Meerut Institute of Engineering and Technology Chand Ramesh

Meerut Uttar Pradesh, India

Ismail National Mahila PG College Saxena Deepti

Meerut Uttar Pradesh, India

Swami Vivekanand Subharti University Kumar Aman

Subhartipuram Meerut, India

Computational study of Ba-doped TiO3 perovskites for solar energy applications The remarkable electrical and optical properties of barium doped TiO₃ perovskite make it an appealing material for optoelectronic applications. This study comprehensively investigates the structural, electrical, and optical characteristics of BaTiO₃ using density functional theory. The electrical characteristics, such as the energy band structure and density of states, were carefully examined. A band gap of 1.92 eV was discovered by the TB-mBJ functional, which is in good agreement with earlier experimental and theoretical findings. The partial density of states analysis reveals that the Ba-p, Ti-d, and O-p states have a significant impact on the material's electronic structure. By evaluating critical variables, the optical properties of BaTiO₃ were investigated. The TB-mBJ approximation indicates that the optical spectrum reveals BaTiO₃ has remarkable properties in the 4–5 eV energy range, making it suitable for solar energy harvesting. Its potential for integration into perovskite solar cells and other optoelectronic devices requiring high optical sensitivity is further corroborated by its low reflectance in this spectrum. 10.18149/MPM.5362025_5 perovskite material TB-mBJ WIEN2K GGA density functional theory https://mpm.spbstu.ru/article/2025.111.5/ 5_kumar_a_et_al.pdf

RAR RUS 63-81 Babol Noshirvani University of Technology Sepahvand Y.

Babol, Mazandaran, Iran

Babol Noshirvani University of Technology Morshedsolouk F.

Babol, Mazandaran, Iran

Babol Noshirvani University of Technology Moazemi Goudarzi A.

Babol, Mazandaran, Iran

Experimental and numerical study of energy absorption in bio-inspired scutoid cellular structures This study investigates the compressive behavior and energy absorption of bio-inspired scutoid cellular structures made from polylactic acid to enhance mechanical energy absorbers used in impact protection. Seven four-cell scutoid specimens with varied transition point positions and wall thicknesses were fabricated using additive manufacturing and tested under quasi-static compression. Numerical simulations were conducted using finite element analysis in Abaqus to complement the experiments. Results show that scutoid structures outperform equivalent honeycomb designs in energy absorption efficiency, with the highest performance achieved when the transition point is located near the mid-height of the cells. Increasing wall thickness improves all key energy absorption indicators. Design of experiments reveals inner wall thickness as the most significant factor affecting energy absorption. The findings demonstrate that optimizing transition point location and wall thickness significantly enhances the crashworthiness of scutoid structures, making them promising candidates for lightweight energy absorbers. 10.18149/MPM.5362025_6 PLA 3D-printed scutoid energy absorption crushing explicit dynamics crushing test https://mpm.spbstu.ru/article/2025.111.6/ 6_morshedsolouk_et_al.pdf

RAR RUS 82-96 0000-0003-2856-7204 St. Ann's College of Engineering and Technology Devireddy Siva Bhaskara Rao

Andhra Pradesh, India

0000-0002-4438-7249 SIR C R Reddy College of Engineering Sunil Ratna Kumar Khandavalli

Vatluru, Andhra Pradesh, India

Swarnandhra College of Engineering and Technology Lalitha Narayana Ravi

Andhra Pradesh, India

0000-0001-5622-4140 St. Ann's College of Engineering and Technology Gopala Rao Thellaputta

Andhra Pradesh, India

R.V.R. & J.C. College of Engineering Tara Chand Vadlamudi

Andhra Pradesh, India

Physical and mechanical performance of surface treated areca fiber and nano alumina reinforced epoxy composites Areca palm stem fiber reinforced epoxy composites modified with alkaline surface treatment and nano alumina were investigated to evaluate improvements in physical and mechanical performance. Composite laminates were fabricated by the hand layup method with 20 wt. % areca palm stem fiber, while sodium hydroxide treatment levels (0, 3, 6, and 9 %) and nano alumina loadings (0, 2.5, 5, and 7.5 wt. %) were varied. The fabricated composite specimens containing 5 wt. % nano alumina, subjected to varying treatment concentrations, consistently exhibited reduced void content and enhanced density. Mechanical characterization showed a significant enhancement in strength and toughness due to the combined effects of fiber surface activation and nanoparticle reinforcement. A 6 % NaOH treatment with 5 wt. % nano alumina resulted in a 53.60 % increase in tensile strength and a 43.05 % increase in flexural strength compared to untreated composites. Maximum impact energy (5.81 J) and hardness (59.5 HV) were obtained at 7.5 wt. % nano alumina with 6 % NaOH-treated fibers. Scanning electron microscopy revealed reduced fiber pull-out and improved interfacial bonding, though voids and microcracks were observed at higher filler loadings. 10.18149/MPM.5362025_7 areca fiber mechanical properties nanofiller NaOH treatment scanning electron microscope https://mpm.spbstu.ru/article/2025.111.7/ 7_devireddy_et_al.pdf

RAR RUS 97-115 0000-0002-1196-8004 Peter the Great St. Petersburg Polytechnic University Vatin N.I.

St.Petersburg, Russia

RUDN University Gebre T.H.

Moscow, Russia

Advancing sustainable construction: comprehensive analysis of the innovative geopolymer bricks Innovative geopolymer brick is an alternative to conventional building materials, notably enhancing its mechanical properties and reducing construction costs. This research used a bibliographic approach based on specific keywords and the Scopus database to collect data, resulting in 490 papers that contain the keyword "geopolymer brick" used as sustainable construction materials between 2004 and 2024. The main approach includes scientometric analysis, in which the patterns of the acquired articles are examined with respect to different characteristics like countries with the highest number of publication sources, the most frequently occurring keywords, affiliations, authors, and articles with more research works that are relevant. Scientometric instruments, such as R-Studio and Vos Viewer, have been important in elucidating the complex network of geopolymer research. The scientometric review facilitates the exchange of innovative concepts and knowledge among scholars from different countries and promotes international collaboration in research. The use of scientific instruments not only amplifies the accuracy of the study analysis but also showcases the multidisciplinary character of modern research, establishing a pattern for forthcoming investigations. It is still necessary to carry out an extensive investigation of the novel geopolymer bricks as an innovative building material while taking the research gaps into account. To do this, it is necessary to examine the results of previous studies and identify the research components and development trends and future endeavours by highlighting the necessity for continued research and the advancement of geopolymers as a cutting-edge and ecologically responsible alternative in construction techniques across the globe. 10.18149/MPM.5362025_8 geopolymer bricks sustainable construction environmental impact innovative building materials scientometric analysis https://mpm.spbstu.ru/article/2025.111.8/ 8_vatin_ni_gebre_th.pdf

RAR RUS 116-129 Universidad Pontificia Bolivariana Gomez Suarez S.

Bucaramanga, Colombia

Universidad Pontificia Bolivariana Guzman-Lopez R.E.

Bucaramanga, Colombia

Universidad CEU San Pablo Gonzalez-Lezcano R.A.

Madrid, Spain

Polylactic acid filaments reinforced with natural fique fibers for 3D printing applications 3D printing offers advantages in terms of geometry customization and material waste reduction; however, the formulation of polymeric composite materials with improved mechanical properties remains a challenge. This study analyzes the use of natural fique fibers as reinforcement in polylactic acid filaments for additive manufacturing applications. In order to improve their compatibility with the polymer matrix, the fibers were subjected to an alkalization treatment and then incorporated into the polylactic acid at a 10 wt. % using a single-screw extruder. The composite filament was characterized by scanning electron microscopy for morphological analysis, differential scanning calorimetry, and thermogravimetric analysis. The test specimens for mechanical evaluation were manufactured by 3D printing and subjected to tensile testing according to ASTM D638-22 using a universal testing machine. In addition, statistical analysis was performed using ANOVA to determine the significance of the differences between pure polylactic acid and the reinforced composite. The differential scanning calorimetry results showed an increase in the glass transition temperature and cold crystallization temperature due to the incorporation of the fibers. Thermogravimetric analysis showed lower thermal stability of the composite, reflected in a reduction in the degradation temperature. Morphological observations indicated low interfacial adhesion between the fibers and the matrix, which contributed to the decrease in tensile strength. However, the composite material had a higher modulus of elasticity, indicating an increase in structural rigidity. 10.18149/MPM.5362025_9 fique fibres 3D printing biocomposite filaments polymer–fibre composites PLA reinforcement https://mpm.spbstu.ru/article/2025.111.9/ 9_roberto_alonso_gonzalez-lezcano_et_al.pdf

RAR RUS 130-144 Dr. B. R. Ambedkar National Institute of Technology Jalandhar Kumar Ashish

Punjab, India

Dr. B. R. Ambedkar National Institute of Technology Jalandhar Bagha Ashok K.

Punjab, India

Dr. B. R. Ambedkar National Institute of Technology Jalandhar Sharma Sumit

Punjab, India

Multi-physics simulation to estimate exposure time for microwave-assisted metallic cast Microwave casting utilizes microwave energy to heat and cast metallic materials. This technique is novel and efficient in comparison to traditional methods. This technique has been applied to cast various metallic materials. There are some factors like dielectric characteristics of processing material, casting setup design, and choices of susceptor and mold, that affect the microwave heating rate. Consequently, determining the optimal exposure time for cast experimentally can be challenging. To address this, simulation studies are valuable. This study involves finite element modeling of microwave casting experimental setup. Using finite element simulations, the exposure times are predicted that are required to cast various metallic powders (Ni, stainless steel SS-316, and Cu) under identical parametric conditions in an electromagnetic environment. The impacts of microwave heating are analyzed through electric field configuration, resistive losses, and thermal distribution within the applicator cavity. The electric field intensity is observed to be maximum (4.46 × 104 V/m) in the susceptor zone, resulting in the highest resistive losses (4.9 × 109 W/m3) in that area. Under the specified conditions, the exposure times to cast Ni, SS-316 and Cu powder into dimensions of 150 × 35 × 3 mm3, are predicted as 2280, 2080, and 1125 s respectively. Experimental results confirm these times with an average percentage error of 13.83 %, demonstrating a close correlation between predicted and actual exposure times. 10.18149/MPM.5362025_10 microwave casting exposure time FE model simulation https://mpm.spbstu.ru/article/2025.111.10/ 10_kumar_a_et_al.pdf

RAR RUS 145-163 59122315900 0000-0002-1572-2108 Kurukshetra University Kumar Rajneesh

Kurukshetra, India

0000-0003-3999-1780 Maharishi Markandeshwar (Deemed to be University) Sharma Nidhi

Mullana-Ambala, India

0009-0000-1827-9335 Maharishi Markandeshwar (Deemed to be University) Rani Vineeta

Mullana-Ambala, India

Elastodynamic response of photothermoelastic plate with moisture due to various sources This current study examines how carrier density and moisture sources cause deformation in an isotropic photothermoelastic moisture plate. We develop simplified two-dimensional equations describing the interaction of heat, moisture, and charge carriers within the material. These equations are expressed in a dimensionless form and solved analytically using Laplace and Fourier transformations to obtain the main field quantities—displacement, stress, temperature, carrier density, and moisture distribution. The theoretical results are validated for silicon material and illustrated graphically. The analysis demonstrates that both carrier density and moisture significantly affect the stress, temperature, and carrier concentration within the plate. Moisture tends to stabilize stress variations and reduce temperature fluctuations, while relaxation times strongly influence oscillation patterns in all field quantities. These results underscore the integrated role of thermal, moisture, and photoelastic effects in shaping the mechanical behavior of semiconducting materials. The proposed model aids in analyzing coupled thermoelastic, moisture, and carrier effects in semiconductors, offering improved prediction of transient responses essential for enhancing thermal stability and reliability in electronic and photonic devices. 10.18149/MPM.5362025_11 isotropic photothermoelastic Laplace transform Fourier transform carrier density source moisture source https://mpm.spbstu.ru/article/2025.111.11/ 11_rani_v_et_al.pdf

RAR RUS 164-181 Veritas University Anya A.I.

Abuja, Bwari-Abuja, Nigeria

Rayleigh waves in a rotating inhomogeneous half-space with magnetic effect under impedance and variable amplitudes of corrugation A mathematical model investigating the dispersions of Rayleigh wave on an inhomogeneous rotating half-space with magnetic field influence, impedance and variable amplitudes of corrugation is presented. Normal mode approach and non-dimensionalization principles were employed to the equations of motion. Derivations of the analytical solutions of the stresses and displacement components occasioned by the wave on the material were achieved. Variable amplitudes of corrugation due to a linear function incorporated as the amplitude of the trigonometric Fourier series and the impedance conditions enriches the material characterizations and paved way in formulating the structure or nature of corrugation at the boundary. Thus, dispersion relations of Rayleigh waves due to homogeneous impedance and inhomogeneous impedance were analytically given and graphically depicted with the variations of the physical parameters. 10.18149/MPM.5362025_12 variable amplitude of corrugation inhomogeneous fiber-reinforcement magnetism rotation of the medium homogeneous and inhomogeneous impedance boundaries dispersion of Rayleigh wave https://mpm.spbstu.ru/article/2025.111.12/ 12_anya_ai.pdf

RAR RUS 182-189 Institute of Mechanics and Engineering Russian Academy of Sciences Yakupov S.N.

Kazan, Russia

Diagnostics of coating and adhesive properties on load-bearing elements of complex shape Protective coatings are used to solve many technical and economic problems. Information on known methods and approaches to studying the mechanical and adhesive properties of coatings is provided. It is noted that modern thin-walled structures, as a rule, have a complex geometry. In this case, protective coatings are formed directly on the surfaces of load-bearing elements. Known adhesion meters have a number of limitations. There are practically no works on determining the mechanical properties of coatings and adhesive formed on surfaces of complex shapes. An effective two-dimensional experimental - theoretical approach to diagnosing the rigidity and adhesive properties of a thin-layer coating formed directly on the surface of a load-bearing element of complex shape is described. At the theoretical stage of the study, the spline version of the finite element method is effective, when varying the properties of the material, we approach the shape of the experimental dome of the considered loading stage. 10.18149/MPM.5362025_13 load-bearing element protective coating mechanical and adhesive properties deformed surface diagnostics complex structure and geometry https://mpm.spbstu.ru/article/2025.111.13/ 13_yakupov_sn.pdf

RAR RUS 190-200 Ufa University of Science and Technology Medvedev Andrey E.

Ufa, Russia

Ufa University of Science and Technology Shaikhulova Aygul F.

Ufa, Russia

Siberian Federal University Motkov Mikhail M.

Krasnoyarsk, Russia

Ufa State Aviation Technical University Murashkin Maxim Yu.

Ufa, Russia

Influence of the core-sleeve boundary interface on the composite Al-Al wire properties The influence of the core-sleeve boundary interface on the mechanical properties and electrical conductivity of the composite all-aluminium wires made of electromagnetically cast Al-0.5 wt. % Fe and Al-1.7 wt. % Fe alloys was studied. For the comparison all-aluminium wires made of same materials were studied as well. Structural analysis was presented by the scanning electron microscopy of the composite all-aluminium wires cross-section, as well as by the fractographic analysis of the failed tensile samples. It was demonstrated that the effect of the core-sleeve boundary increases with the increase in amount of alloying elements in the composite all-aluminium wires components. The core-sleeve boundary in the composite all-aluminium wires acts as a buffer for the deformation thus the amount of the deformation, that otherwise would be distributed gradually in the all-aluminium wires, is distributed uneven between the core and the sleeve of the composite all-aluminium wires, accumulating more within the composite all-aluminium wires sleeve. The major influence of the core-sleeve boundary is noted in yield strength and ductility of the wires, while electrical conductivity and especially ultimate tensile strength remain mostly unaffected. 10.18149/MPM.5362025_14 aluminium alloys electromagnetic crystallization composite wire mechanical strength ductility electrical conductivity https://mpm.spbstu.ru/article/2025.111.14/ 14_medvedev_et_al.pdf

RAR RUS 201-212 University of Djillali Liabes Belaribi A.

Sidi Bel Abbès, Algeria

King Fahd University of Petroleum and Minerals Chekalil I.

Dhahran, Saudi-Arabia

University of Djillali Liabes Miloudi A.

Sidi Bel Abbes, Algeria

University of Djillali Liabes Ben Messaoud M.A.

Sidi Bel Abbès, Algeria

University of Laghouat Zoukel A.

Laghouat, Algeria

Effect of welding parameters and response surface method based on prediction of maximum temperature generated during friction stir welding of AA3003 Friction stir welding generates significant temperature increases, leading to microstructural changes that influence the mechanical properties of the material. Temperature control is therefore essential to ensure the quality of the welded joint. This study aims to model and predict the maximum temperature generated during the friction stir welding of aluminum alloy 3003, based on three key operating parameters: rotation speed, feed rate, and tool inclination angle. The response surface method was used to develop a robust predictive model and evaluate the individual and combined effects of these parameters on the thermal response. The results reveal that the most influential parameters are, in order, rotation speed, tool inclination angle, and feed rate. They also indicate that the maximum temperature increases significantly with rotational speed and angle of inclination. In contrast, it decreases as the feed rate increases. The model obtained has excellent predictive power, validated by a low root mean square error of 4.41 °C and a coefficient of determination R² of 0.972. 10.18149/MPM.5362025_15 FSW Tmax RSM prediction rotation speed https://mpm.spbstu.ru/article/2025.111.15/ 15_belaribi_et_al.pdf

RAR RUS 213-223 Maharishi Markandeswar (Deemed to be) University Himanshu

Haryana, India

Maharishi Markandeswar (Deemed to be) University Arora R.

Haryana, India

CGC University Kushdeep

Punjab, India

Investigating the effect of process parameters on EDM performance of Inconel 725 alloy In aerospace and automotive sectors, electrical discharge machining is essential for shaping hard-to-machine materials like Inconel 725. Using Taguchi's L16 orthogonal array, this study examines how electrode shape (round and square), peak current (8 and 12 A), pulse-on time (100 and 200 µs), and pulse-off time (1.2 and 1.6 µs) affect material removal rate and surface roughness. The study found that raising peak current from 8 to 12 A considerably improved material removal rate from 0.0593 to 0.1417 mm³/min. The maximum material removal rate was reached with a round electrode, 12 A current, 200 µs pulse-on, and 1.2 µs pulse-off duration. However, this setting resulted in the roughest surface finish (9.407 µm). However, the square electrode had better surface quality, with the lowest SR value of 5.965 µm at 8 A, 100 µs pulse-on, and 1.6 µs pulse-off. enhanced pulse-on time (200 µs), enhanced material removal rate by 47.77 %, but shorter pulse-off time (1.2 µs) led to more efficient erosion owing to higher discharge frequency. The findings help precision machine advanced alloys like Inconel 725 by emphasizing the need for electrical discharge machining parameter selection to balance high material removal rate and surface integrity. 10.18149/MPM.5362025_16 Inconel 725 alloy electrical discharge machining DOE material removal rate surface roughness https://mpm.spbstu.ru/article/2025.111.16/ 16_himanshu_et_al.pdf