The objectives of this research work are to determine the influence of effect of spark electric discharge machine on the recast layer and indeed the strength properties of the AA 6061-Graphene composites. The green compacts were subjected to microwave sintering at 550 °C for 30 minutes. The sintered samples are then hot extruded at 300 °C to flat plates and air cooled later. The extruded samples are subjected to mechanical characterization for density, hardness and tensile strength. Further, spark EDM process is used to machine the extruded samples. The SEDM processed samples with the aluminium alloys 6061-Gr composites compared with the as extruded condition. The hardness studies on the samples are carried out using Rockwell hardness testing machine with B scale as per standards, Tensile strength studies are carried out in Instron Universal Testing Machine with a standard strain rate of 0.75 mm/min. Recast layer of the SEDM samples is studied using HR-SEM and the thickness of the recast layer is recorded. The influence of the recast layer thickness on the tensile strength the extruded composite is studied. The surface roughness and material removal rate (MRR) of the extruded composites after the SEDM process also studied in correlation with the strength properties.