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The growing demand for light composite materials is the new trend in engineering solicitations. The objective is to fabricate light weight composite material through less expensive method. In this work, nine different composites have been fabricated with A6061 as base matrix and reinforced with 3%/6%/9%wt%B4C having particle sizes of 30µm, 40µm and 60µm respectively. The investigation of the actual density and hardness of the fabricated composite is the major task. The densities of the fabricated composites were investigated with Two-way Analysis of Variance(ANOVA). Also the densities of the composites were predicted with Taguchi, regression and Poisson method. From all of these fabricated composites 60µm size, 9% wt B4C particle reinforced A6061/B4C composite shows lighter density and this value were nearest to Poisson predicted value.

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Electrical Discharge Machining (EDM) is considered as the much traditional, adaptable and unconventional machining process that is proficient in generating complicated structures. Further, it is self-sufficient over the mechanical properties of workpiece materials only if it is conductive. The viability of the EDM process regarding the application types might get considerably improved with the constant enhancement in the personification of numerical control and the metal removal efficacy. This survey intends to make a review of 65 papers related to the optimization and modeling of EDM process machining. The analysis is thus made with regards to the following factors like Al alloy composite in Die Shrinking EDM, Optimization and Al metal matrix composites. Particularly, the hybrid optimization models in various papers are analyzed concerning their logic. Further, the algorithmic and parametric analysis is also made with the contributed papers. Finally, the research gaps and challenges in this EDM processing are discussed, which would pave the way for efficient research works in this area.

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