Maximum coating thickness achievable with an 8KW laser cladding system

Typical Coating Thickness Range

An 8 kW laser cladding system is capable of depositing coating layers between 0.5 mm and 2.5 mm in a single pass, depending on the material and process parameters. For thicker builds, multiple passes can be performed with precise overlap control, allowing total thicknesses of up to 6–8 mm while maintaining structural integrity and metallurgical bonding.

Influence of Material Type

High-performance superalloys such as Inconel 718, Stellite 6, and Hastelloy C-276 allow for stable multi-layer cladding. However, heat-sensitive materials may require controlled cooling cycles and intermediate finishing to prevent porosity or cracking.

Need for Post-Processing

For multi-layer cladding, post-treatment becomes essential. Processes such as hot isostatic pressing (HIP) and heat treatment improve densification and reduce residual stress in thicker coatings. Dimensional accuracy and final tolerances can be restored using superalloy CNC machining.

Application Considerations

Thicker coatings are most frequently used in critical sectors such as power generation and oil and gas, where wear resistance and corrosion protection are essential. In marine and mining industries, thicker laser-cladded layers are preferred for impact resistance and dimensional recovery during axle or shaft repair.