The major negatives of Arc Welding (AW) techniques are high heat input into the part and, depending upon the particulars, relatively high dilution of the clad material (that is, unwanted mixing of the base material into the clad layer). Heat input into the part can cause mechanical distortion which maycreate the need for further processing after cladding.

In Thermal Spraying (TS) techniques, the clad material, in powder form, is melted by a flame or electricity and then sprayed on to the work-piece. In most cases, this is a low-heat process, typically <200°C. 

Primary advantages of all thermal spraying techniques is the low heat input into the part, which means there is no heat affected zone (HAZ) and minimal dilution.

The biggest drawback of thermal spraying is that the bond between the clad layer and the substrate material is mechanical, not metallurgical in nature. This can lead to problems with adhesion and poor wear resistance, especially with pinpoint loading.

Also, thermal spray claddings are typically much stronger in compression than in tension and often exhibit some level of porosity.

Laser cladding typically produces a high quality clad having extremely low dilution, low porosity and good surface uniformity.

Moreover, laser cladding transfers minimal heat input into the part which largely eliminates distortion and the need for post processing. It also avoids the loss of alloying elements or hardening of the base material.

In addition, the rapid natural quench experienced with laser cladding results in a fine grain structure in the clad layer which tends to improve the corrosion resistance.

The technical benefits of laser cladding over other non-laser welding techniques include:

1. Low dilution rates (<3%)
2. Uses less filler material
3. Higher hardness
4. Small Heat Affected Zone (HAZ)
5. Strong Metallurgical Bonding (vs mechanical one, provided by AW and TS)

The business benefits include extra protection to components thus longer life, up to a factor of five. The process is fast, accurate and easy to automate. This increases  production and reduces Turn Around Times (TRT). Once the process is validated it is readily adopted because of the proven benefits.

The benefits to the customer, are:

1. Building new parts with assured longer life of elements subjected to wear and abrasion.
2. Rebuilding worn parts at a fraction of replacement cost.
3. Savings in maintenance costs when rebuilding on site and in situ.
4. Hardfacing / Cladding alloy only needs to be deposited where it is needed and not have to cover the whole component.
5. Breakdown time or scheduled maintenance shutdown is reduced thus increasing work efficiency.

The most common cladding materials are nickel alloys and iron/chromium alloys used in wear resistance and high stress abrasion.