Abstract: A hybrid laser cladding nozzle configured to both powder feed and wire feed a cladding layer onto a substrate surface is disclosed. The hybrid laser cladding nozzle may comprise a central laser channel that is configured to convey a laser beam onto the substrate surface to produce a laser beam spot thereon. The hybrid laser cladding nozzle may further comprise a powder channel coaxial to the laser channel that is configured to feed a powder material onto the laser beam spot, and at least one wire channel laterally disposed with respect to the laser channel and the powder channel that is configured to feed a wire onto the laser beam spot. The laser beam spot may be configured to at least partially melt the powder material and the wire to produce the cladding layer on the substrate surface upon resolidification.

Abstract: A method of forming a layer of cladding material on a component includes performing a metal deposition process to deposit cladding material onto a surface of the component and onto a mold member. A metallurgical bond is formed between the cladding material and the component, but not between the cladding material and the mold member. The mold member may be removed after the metal deposition process, and the layer of cladding material can be processed to modify its shape.