Laser Cladding VS Thermal Spray – Which Will Blow Your Mind?

laser cladding

Table of Contents

Laser Cladding VS Thermal Spray

Laser cladding and thermal spraying play crucial roles in the field of surface coating, offering distinct methods of protection and enhancement for material surfaces. Widely applied in industrial manufacturing, aerospace, energy, and other sectors, these advanced coating technologies exhibit notable differences.

Let’s delve into laser cladding first. Laser cladding involves using a high-energy laser beam to instantaneously melt metal powder or wire, spraying it onto the substrate’s surface. This method boasts high precision, a low heat-affected zone, and exceptional coating quality. Common applications include repairing damaged components, increasing surface hardness, and enhancing wear resistance.

In contrast, thermal spraying encompasses various techniques utilizing flame, plasma arcs, or high-speed gas jets to heat powder or wire to a molten state before spraying it onto the substrate’s surface. Forms of thermal spraying include conventional flame spraying, plasma spraying, and high-velocity flame spraying. This approach is cost-effective and suitable for large-area applications or coating requirements for substantial workpieces.

Eatonite Coating

When comparing laser cladding and thermal spraying, precision and heat-affected zones are primary considerations. 

  • Laser cladding, with its high-energy laser beam, achieves highly accurate coating in tiny areas.
  • Thermal spraying, using traditional heating methods, results in relatively lower coating precision.

Additionally, laser cladding’s smaller heat-affected zone aids in reducing substrate heat impact, minimizing deformation and cracks.

The macro morphology of laser cladding tracks a 90Cr10Ni b 80Cr20Ni c 70Cr30Ni
HAZ of laser cladding

Coating quality is another critical factor in comparing the two technologies.

  • Laser cladding, due to its use of a laser beam to instantaneously melt metal powder, forms a dense and uniform coating, resulting in superior quality.
  • Thermal spraying, with gas and particle collisions during spraying, is prone to creating pores and loose coating structures, leading to relatively poorer coating quality.
laser cladding with good quality

Moreover, cost is a significant factor depending on specific application requirements.

  • Thermal spraying, with lower equipment and raw material costs, is suitable for scenarios where coating costs are not a primary concern.
  • Laser cladding, requiring high-energy laser equipment, is relatively more expensive but excels in applications demanding high coating quality and precision.


In conclusion, laser cladding and thermal spraying each have their strengths and weaknesses. The choice between these technologies depends on specific application needs. Laser cladding is preferable when strict requirements exist for coating precision, quality, and minimal heat impact. On the other hand, thermal spraying is more suitable for cost-conscious applications, large-area treatments, or general coating needs. As technology advances, both methods may see further innovation and applications, unlocking more possibilities in the field of surface coating.

A Chutian Laser Cladding System
A Chutian Laser Cladding System
Laser Welding Tips

Laser welding tips: Laser welding is a precise and efficient method for joining materials, particularly when dealing with thicker plates....

what is a 3in1 laser welder?

What is a 3-in-1 Laser Welder? A 3in1 laser welder is a state-of-the-art welding device that combines three essential processes...

Laser Tyre Mold Cleaning

Introduction to Laser Clean Tyre Mold Tire molds play a crucial role in the production of high-quality tires. However, over...

Shield Gas in Laser Welding

Laser Welding Gas In laser welding, shielding gas is utilized to enhance the welding process and prevent deposits on the...

Hi, I am the author of the website and also a laser equipment engineer, if you have any questions about industrial lasers, please contact me by clicking the link below

Skip to content