This study aims to determine the performance of brass coated wire on novel hybrid aluminum metal matrix composites (MMCs) using Wire Electric Discharge Machine (WEDM). To fabricate the hybrid aluminum-based hybrid (MMCs), aluminum AA6061 were selected as a base material, while Graphite (Gr) and Silicon Carbide (SiC) were used as reinforcement materials. Brass wire with a protective coating was used by the experimental group, while brass wire alone was used by the control group. The specimen was fabricated using a stir casting process, and its phase composition was 92% Al6061, 5% SiC, and 3% Gr. A total of 34 samples were selected for the study and 17 samples from each group were used to evaluate the shear strength of MMCs. Compared to the uncoated brass wire, the zinc coated brass wire has a wider kerf as shown by a significant value of 0.000 < 0.05 with a 95% confidence interval. There is a significant difference between the two groups. The maximum material removal rate (MRR) of 134 mg/min was achieved by a zinc wire-coated electrode. Similar studies were carried out on a hybrid composite made of 92% Al6061/5% SiC, and 3% Gr to validate the proposed method. The effect of each machining parameter was investigated using analysis of variance and confirmatory tests. It was discovered that the rate of material removal increased with an increase in pulse-on time and pulse current but decreased with an increase in voltage.

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