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.