Objective is to modify the surface of aluminum workpiece by electro discharge machining (EDM) process using TiC/Cu green compact tool electrode. Surface modification by EDM process is a newly invented, fairly cheap and very competitive technique as compared to other surface modification techniques, such as Physical Vapor Deposition (PVD), Chemical Vapor Deposition (CVD) and so on. By using ordinary EDM machine tool and dielectric, a very hard layer of the desired material can be created successfully. Powder metallurgy (P/M) green compact or semi-sintered tool electrodes are used to create hard layer(s) on the work surface by transferring the constituent materials of the tool electrode on it in the form of a deposited layer which will enhanced mechanical and tribological properties, and surface integrity. The resulting coated surfaces have higher hardness, corrosion resistance and wear resistance, and less cracks. Box-Behnken approach of Response Surface Methodology (RSM) used to investigate the effects of the various process parameters. Using the powder metallurgy green compact TiC/Cu tool electrode, a hard layer of 2325 HV has been created about 60 ? layer thickness.