: After the twentieth century , some important soft magnetic materials such as Fe-Ni, Co-Fe-Ni and Fe-Si alloys were noted due to the continuous development of communication technology, magnetic recording and magnetic sensors. The iron- nickel alloys are used in magnetic sensors. Iron- nickel alloys have unique features such as low thermal expansion coefficient and soft magnetic properties, which are the main reasons for wide application in industry. In the first step of this research, iron- nickel alloys were produced using direct current electrodeposition. Then nanostructure composite of iron- nickel/ tungsten carbide was produced using direct and pulse current electrodepodition in a simple chloride bath. Effects of various parameters such as applied pulse current ,temperature, pH and current density on the composition and morphology of product, as well as the current efficiency, production rate and specific energy consumption were examined. Morphology, chemical composition and microstructure of samples were studied by scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS) and x-ray diffraction (XRD) analysis. The results obtained from the direct current electrodepodition showed that increasing the pH reduced the iron and increased the nickel in the product. The morphology of nanostructure composite electrodeposited by pulse current was spherical but for direct current was polyhedral. The current efficiency and production rate for nanostructure composite increased and specific energy consumption decreased as pH increased. By increasing temperature, current efficiency and production rate were reduced and specific energy consumption was increased. For the pulse electrodeposition, Ni slightly increased as pH was increased. The increase of Ni in nanostructure composite obtained by pulse electrodeposition led to change the morphology from spherical to star like. By increasing the electrolyte temperature from 40°C to 70°C, nickel content of product increased from 18 to 61 wt%, iron content reduced from 74 to 21 wt%, and tungsten carbide increased from 8 to 18 wt%. Also by increasing temprature anomalous electrodeposition was declined. Results obtained from applied pulse current showed that the ratio of Ni/Fe in products is greater than direct current. The morphology obtained by direct current electrodeposition was more uniform. Lower current efficiency, lower production rate and higher specific energy consumption were obtained in pulse electrodeposition compared with direct current.This could be due to the higher rate of hydrogen production in pulse current electrodeposition than the direct current one. Keywords : electrodeposition, iron- nickel, tungsten carbide, pulse, composite
