Laser cladding with wire feeding is an advanced surface modification technology that has experienced significant growth in recent decades due to its high deposition rate,


efficient material utilization, strong metallurgical bonding, low dilution ratio, and minimal heat-affected zone. Despite these advantages, the thermo-physical and metallurgical mechanisms underlying the laser wire cladding process are complex, making it challenging to identify the interrelationships among materials, design, process parameters, and performance using traditional expertise or conventional expert systems. This study presents a comprehensive overview of process development, parameter optimization, numerical simulations, and real-time sensing in laser hot-wire cladding using a high-power direct diode laser. A mathematical model was developed to correlate geometric characteristics and dilution ratios with laser processing parameters, establishing the desired process window to enhance deposition rates and achieve high-quality clad layers. To address the effects of residual stresses on mechanical integrity and fatigue life, a three-dimensional uncoupled thermo-mechanical finite element model was developed to predict temperature evolution and thermally induced residual stress distribution in cladding process. Furthermore, a multi-sensor monitoring system, integrating a high-speed camera, spectrometer, and infrared camera, was employed to detect real-time variations in cladding conditions. This study also introduces the concept of a digital twin for the laser wire cladding system, aimed at providing interactive feedback among materials, design, process parameters, and performance to enhance the overall process control and quality.