Nowadays, by advancing the machining process and industries, it needs to create a complex material shape with high-level hardness needs to be created. Thus, the introduction of electro-discharge machining (EDM) as one of the beneficial methods is acceptable and remarkable. Numerous experiments are conducted by surrounding the mixed powder materials (Al, Alumina, Silicon, etc.) in the EDM process. In thisThis way, it’s investigated, analyzed, and comprised of the topological and metallurgical heat affect zone (HAZ) on the surface of α+β-Ti-6Al-4V, is called “Ti6-4”, as the workpiece, that it’sis used toparticularly on sensitive applicants especially. After comparing and investigating between two stages, without powder mixed and with a certain amount of powder, it’s considered an optimum point within adding powder inwhen 2.5 g/l of Aluminum (AL) powder is added. thisThis point led to an increase by 22% in material removal rate (MRR) and by 10% tool wear rate (TWR) in percent of 22, and 10, respectively. The best morphology and metallurgical resultresults are seen with 2.5 g/l of Al powder, in less than 10 µm size, and 15 A as peak current. Metallurgical results byof the Field Emission-Scanning Electron Microscopy (FE-SEM) and Element mapping analysis are shownshow that duringwhen adding the powder in the EDM also will have thinner, the thickness of the recast layer with lesser thanwill be thinner and with less metallurgy defects, and also, probably, are made oxides, carbides and intermetallic phase composition, andare created - they have been analyzed its phase diagram. Furthermore, powder mixed electro-discharge machining (PMEDM) also increases machining performance by improving MRR and reducing TWR, machining time, and metallurgy defects.