Abstract: A model of consecutive Electro spark deposition was built, by using birth and death element method and establishing suitable boundary conditions, to analyze the residual stress on WC-12Co coating by consecutive electro spark deposition. Curves of variation of stress at different depths with time were derived with finite element software ANSYS. It is found that the residual stress was mainly parallel to the surface of workpiece, and the maximum tensile stress appeared on the coating surface. The model of consecutive electro spark deposition was used to analyze the influence of process parameters on the residual stress and to predict the most suitable process parameters window. Electro spark deposition experiments were conducted to verify the simulated results.