Abstract: Fabrication of the thin-wall metallic feature by laser cladding is experimentally studied, and the factors affecting it are analyzed. The capacity to form thin-wall metallic features is important for forming small parts and those involving thin walls. This capacity is poor since the thoughts about laser cladding treatment mislead the process. Laser cladding formation differs to laser cladding treatment. In the presented experiment, a low-power CO2 laser with small light spot, unlike that for treatment, is applied for single-pass cladding. The following conclusions are drawn：①If the scanning speed, powder feed rate and other process parameters are matched suitably with the laser, a thin wall with thickness down to 0.4 mm can be achieved. ②The wall thickness is dependent on the process parameters and the height. ③The coaxialness of the centerline of the laser beam with that of the powder flow and the steadiness of the powder feed rate both affect forming thin-wall metallic features.

Key words: Forming, Laser cladding, Thin-wall feature