Progress in material systems, process control, and performance enhancement of laser cladding technology

Laser cladding technology is a principal enabling technique for advanced surface engineering and high-value component repair. Its intrinsic merits include highly localized energy input, minimal thermal distortion, robust metallurgical bonding with the substrate, extensive material applicability, and high potential for automation, positioning it as a superior solution for restoring and enhancing component functionality. The process not only revives worn parts but also engineers surface properties to achieve performance that meets or surpasses original equipment specifications. The ultimate success of laser cladding applications critically depends on the quality and functional characteristics of the deposited clad layers. This review systematically surveys the state-of-the-art in laser cladding technology, with a tripartite focus on material systems and compatibility strategies, process parameter optimization for defect-free deposition, and evaluation of in-service performance and functional reliability. By consolidating current knowledge, highlighting key advancements, and identifying persistent challenges, this review delineates promising future research directions and technological trends in this rapidly evolving field, underscoring its significant potential for sustainable manufacturing and the circular economy.