A new deposition alloying process using Micro-EDM was developed. Using the energy released by the electrical discharge, material from the tool electrode is melted and deposited over the work surface. When a rotating bi-metal tool electrode is fed towards the work surface, the alloying between its elements occurs during process. The obtained results of the alloying between nickel and iron are presented in the present paper, when the components of the bi-metal tool electrode are made of YNi-1 (nickel alloy used in TIG welding — JIS standard) and medium carbon steel (S45C — JIS standard). X-ray and EDS analysis have shown that the chemical composition of the obtained deposit can be controlled and is proportional to the cross sectional area of each element present in the bi-metal electrode. With this process, a material with the same composition of Invar was successfully deposited.

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