This work uses Electrochemical Discharge Machining (ECDM) to investigate the machining performance of Al6061-4%SiC-8%B4C hybrid composites. The study investigates how Material Removal Rate (MRR), Tool Wear Rate (TWR), and hardness are affected by voltage, electrolyte concentration, pulse-on time, and pulse-off time. For statistical modeling, an ANOVA and a Taguchi L9 orthogonal array were employed. Results indicate that higher voltage significantly enhances MRR and increases TWR, while optimizing pulse parameters improves machining efficiency. Increased hardness (165 HV) with the addition of 4% SiC and 8% B4C improved machining stability and wear resistance. Because it offers a balanced strategy for raising MRR while controlling TWR and tool life, ECDM is a practical technology for machining hybrid composites in aerospace and automotive applications. Future research should investigate better electrode materials and electrolyte modifications to further increase machining performance. While ECDM shows promise for hard-to-machine materials, the specific interaction and performance analysis of this technique on the Al6061matrix reinforced with the hybrid combination of SiC and B4C has not been systematically investigated, leaving a gap in optimizing the process parameters for industrial application. The results showed that the optimal processing conditions achieved a maximum Material Removal Rate MRR of 4.25 g/min, representing 32% improvement compared to the least effective parameters. Furthermore, the statistical model confirmed that Voltage is the most significant factor, contributing to approximately 78.5% of the total MRR variation, while TWR was effectively controlled to a minimum of 0.012 g/min under specific pulse conditions.
