Abstract: The invention both rotates and oscillates the electrode at the same time to increase the quality of materials deposited onto a substrate during an pulse fusion surfacing process. The PFS spark rate is also varied to further increase the quality and effectiveness of the PFS process. Electrode oscillation keeps the electrode from welding to the substrate surface and electrode rotation maintains even wear on the electrode work surface. An evenly worn electrode surface allows the PFS process to generate more consistent substrate surfaces. In addition, electrode oscillation neutralizes "run away" conditions and varying spark torque that occur with electrodes that are only rotated. The spark rate is varied according to various PFS process parameters (e.g., substrate material) to further improve the quality of the PFS deposition layer.