Resistance spot welding (RSW) is widely used as a main joining technique in industry and the electrode caps are frequently replaced because of degradation during service. In this study, G type copper RSW were coated with Fe Ni based Fe3Al, FeAl, Ni3Al, NiAl alloys by Electro-Spark Deposition (ESD), providing resistance to hot deformation, oxidation Zn evaporation from sheet metal. The ESD teste...