Aluminum bronze which has high corrosion resistance, high strength and easy castability is recentlyexpected as a new plastic mold or a shell mold core material in place of steel conventionally used. Onthe other hand, it is reported that the EDMed surface with metal powder mixed fluid has smallersurface roughness and higher resistance to corrosion. From these points of view, EDM characteristicsof aluminum bronze were experimentally investigated in the first place. Then, EDM with nickelpowder mixed fluid for smoother surface roughness and higher surface integrity was proposed andevaluated. Main conclusions obtained in this study are as follows:(1) The metal removal rate in EDM of aluminum bronze is approximately the same as that of steel,and no electrode wear EDM is possible.(2) The EDMed surface with nickel powder mixed fluid has a smaller surface roughness than that inconventional EDM with kerosene type fluid.(3) Resolidified layer containing nickel can be generated and the thickness of the layer becomeslarger and uniform with an increase of nickel powder concentration in machining fluid.(4) The EDMed surface with nickel powder mixed fluid becomes harder than that with kerosenetype fluid and it has high resistance to sand abrasion.
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