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The critical components in earlier were manufactured by mild steel but due to low corrosion resistance, stainless steel and aluminium alloy are being utilised. However a component of aluminium alloy has to be enriched by anodizing for long durability and better corrosion resistance. But peel off, pit formation, low adhesion and white rust formation are still the downfalls faced by the industries in the coated components over cyclic duration. High-Velocity Oxy-Fuel (HVOF) thermal spraying is an adaptable method that can produce high-density coating with less than 1% porosity, high resistant to chemical environment providing better adhesion and increase the life of mating components. Though stainless steel and anodized aluminium alloy offers far superior life span and corrosion resistance but still more expensive than mild steel.

Hybrid Composite materials meet a major demand in current industrial market through mixture of various percentages of metal compositions at different levels. One such material, which is most widely employed, is aluminum. Aluminum hybrid metal matrix composites is substituted with conventional alloys in order to meet the rigid, high-end requirements at major industries. In this work, it is reinforced with Aluminum-Tungsten Carbide-Graphite composite and fabricated using the stir casting process. Die sinking electric discharge machining (EDM) process is preferred over conventional process for the purpose of machining complex shaped materials with accuracy. The optimization of minimizing surface roughness and maximize material removal rate is essential to increase the effective and efficient usage of hybrid composites.