Resistance Spot Welding (RSW) is a widely used technology. And the rapid wear is the main reason for the short life of RSW electrodes. To improve electrode life during RSW, a novel ultrasonic-aided electro-spark deposition technology (UESD) and device are proposed in this paper. The WC metallurgical bond coating was fabricated on the surface of CuCr1 electrodes by UESD, and some experimental results were also analyzed. Moreover, the surface morphology of WC coating was studied by SEM and the quality of coating wear resistance was analyzed through experimental method. This study provides a novel way to extend the life of common moulds and RSW electrodes.