A method of surface treatment of an electrically conductive workpiece includes applying a powder coating to the workpiece in a green state before being welded to the workpiece using ESD. The coating is a heterogenous mixed powder of electrically conductive particles. It may be a High Entropy Alloy having at least five elements, each being 5% to 35% atomic fraction of the mixture. The welding occurs at contacts of less than 10 J. The powder may be formed as a slurry, whether in an aqueous solution or with a binder; and may be applied as a slurry or as a paste. It may be applied to non-flat and non-horizontal surfaces. Once deposited, it may be peened after ESD arcing. The ESD applicator may use a welding rod that is of a different material from either the powder mixture or the workpiece.

A method of surface treatment of an electrically conductive workpiece includes applying a powder coating to the workpiece in a green state before being welded to the workpiece using ESD. The coating is a heterogenous mixed powder of electrically conductive particles. It may be a High Entropy Alloy having at least five elements, each being 5% to 35% atomic fraction of the mixture. The welding occurs at contacts of less than 10 J. The powder may be formed as a slurry, whether in an aqueous solution or with a binder; and may be applied as a slurry or as a paste. It may be applied to non-flat and non-horizontal surfaces. Once deposited, it may be peened after ESD arcing. The ESD applicator may use a welding rod that is of a different material from either the powder mixture or the workpiece.

A welding electrode apparatus may be mounted to a robot that presents it to a workpiece along a pre-programmed path conforming to the surface of the workpiece. The welding electrode apparatus has a first drive for rotating the welding electrode about its own axis. The electrode handle has a second rotating drive having an imbalance to impose vibration on the welding rod transverse to the axis of the rod. The first drive may turn relatively slowly; the second drive may turn more quickly. The first drive has an electrical pickup by which to carry DC power to the electrode. The two rotating drives impose two frequencies of vibration into the apparatus, causing a make-and-break contact for low power spark deposition, while at the same time causing the electrode to bounce and impact the surface. The forward end of the apparatus may include a cowling and a delivery line to provide shielding gas to the electrode.

A welding electrode apparatus may be mounted to a robot that presents it to a workpiece along a pre-programmed path conforming to the surface of the workpiece. The welding electrode apparatus has a first drive for rotating the welding electrode about its own axis. The electrode handle has a second rotating drive having an imbalance to impose vibration on the welding rod transverse to the axis of the rod. The first drive may turn relatively slowly; the second drive may turn more quickly. The first drive has an electrical pickup by which to carry DC power to the electrode. The two rotating drives impose two frequencies of vibration into the apparatus, causing a make-and-break contact for low power spark deposition, while at the same time causing the electrode to bounce and impact the surface. The forward end of the apparatus may include a cowling and a delivery line to provide shielding gas to the electrode.

A welding electrode apparatus may be mounted to a robot that presents it to a workpiece along a pre-programmed path conforming to the surface of the workpiece. The welding electrode apparatus has a first drive for rotating the welding electrode about its own axis. The electrode handle has a second rotating drive having an imbalance to impose vibration on the welding rod transverse to the axis of the rod. The first drive may turn relatively slowly; the second drive may turn more quickly. The first drive has an electrical pickup by which to carry DC power to the electrode. The two rotating drives impose two frequencies of vibration into the apparatus, causing a make-and-break contact for low power spark deposition, while at the same time causing the electrode to bounce and impact the surface. The forward end of the apparatus may include a cowling and a delivery line to provide shielding gas to the electrode.

A welding electrode apparatus may be mounted to a robot that presents it to a workpiece along a pre-programmed path conforming to the surface of the workpiece. The welding electrode apparatus has a first drive for rotating the welding electrode about its own axis. The electrode handle has a second rotating drive having an imbalance to impose vibration on the welding rod transverse to the axis of the rod. The first drive may turn relatively slowly; the second drive may turn more quickly. The first drive has an electrical pickup by which to carry DC power to the electrode. The two rotating drives impose two frequencies of vibration into the apparatus, causing a make-and-break contact for low power spark deposition, while at the same time causing the electrode to bounce and impact the surface. The forward end of the apparatus may include a cowling and a delivery line to provide shielding gas to the electrode.