Electrospark deposition (ESD) is a coating process that is featured by low heat input to the substrate. Low coating efficiency and other limitations influence its wider application. The present paper introduces newly designed ESD equipment, by which a higher coating rate can be reached. The relationship among coating thickness, surface roughness, and process parameters such as pulse energy, pulse frequency, and deposition time are presented. Electrospark deposition coating by the new equipment on AISI 1045 steel (with WC-8% Co as electrode) increases the wear resistance by 5 to 8 times. The micromechanism is investigated by scanning electron microscopy observation.
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