How does laser cladding compare to traditional surface coating methods?

Precision and Heat Control

Laser cladding delivers significantly higher precision than traditional coating methods such as PTA welding, thermal spray, or MIG/TIG overlays. The narrow heat-affected zone reduces distortion and preserves base material properties. This precision is essential for complex geometries and high-value components such as turbine vanes and combustion parts made via single crystal casting or vacuum investment casting.

Bond Quality and Metallurgical Integrity

Unlike thermal spraying—which creates only mechanical adhesion—laser cladding forms a metallurgical bond with the substrate. This ensures higher resistance to wear, corrosion, and fatigue, especially when using high-performance alloys such as Hastelloy C-276 or Stellite 6.

Repair Capability for Critical Parts

Laser cladding allows selective restoration of worn surfaces without altering undamaged areas, making it ideal for precision repair of components used in power generation, marine, and oil and gas industries. Traditional processes often require large heat input, leading to distortion and higher post-machining requirements.

Post-Processing Efficiency

Due to accurate material deposition and lower dilution, laser-cladded surfaces require less machining effort to reach final tolerances. The process integrates efficiently with finishing via superalloy CNC machining and strengthening treatments such as heat treatment or HIP.

Overall Performance Advantage

Laser cladding provides superior wear resistance, corrosion protection, and fatigue performance compared to traditional surface coatings. It is increasingly preferred for critical applications in military and defense and aerospace, where reliability under extreme conditions is essential.