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<p>Extreme high-speed laser cladding (EHLC, Extreme High-Speed Laser Cladding) has attracted attention in material surface modification, due to its high energy density (3&#xa0;kW/cm<sup>2</sup>), high deposition rates (20–500&#xa0;m/min), and notable coating performance. However, the rapid heating and cooling inherent to EHLC can introduce stress concentrations within the coating, resulting in defects such as cracks and porosity that may degrade performance. Process optimization is essential for minimizing these defects and advancing coating quality. This paper reviews current research in EHLC technology, beginning with an overview of its fundamental principles and criteria for cladding material selection, including powder characteristics. The effects of processing parameters, such as laser power, scanning speed, and overlap ratio, on coating quality are analyzed alongside established optimization methods. The influence of external field-assisted technologies on coating properties and their mechanisms for regulating microstructures have been discussed. Finally, future trends in EHLC optimization are identified, with the goal of supporting broader adoption in material modification.</p>

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Process optimization of extreme high-speed laser cladding: materials, parameters, external field assistance, and future trends

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年6月24日

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  • Bingyan Duan,
  • Haichao Zhao,
  • Naiming Lin,
  • Li Zhou,
  • Xin Wang,
  • Guozheng Ma,
  • Haidou Wang,
  • Yucheng Wu

摘要

Extreme high-speed laser cladding (EHLC, Extreme High-Speed Laser Cladding) has attracted attention in material surface modification, due to its high energy density (3 kW/cm2), high deposition rates (20–500 m/min), and notable coating performance. However, the rapid heating and cooling inherent to EHLC can introduce stress concentrations within the coating, resulting in defects such as cracks and porosity that may degrade performance. Process optimization is essential for minimizing these defects and advancing coating quality. This paper reviews current research in EHLC technology, beginning with an overview of its fundamental principles and criteria for cladding material selection, including powder characteristics. The effects of processing parameters, such as laser power, scanning speed, and overlap ratio, on coating quality are analyzed alongside established optimization methods. The influence of external field-assisted technologies on coating properties and their mechanisms for regulating microstructures have been discussed. Finally, future trends in EHLC optimization are identified, with the goal of supporting broader adoption in material modification.