Laser processing systems capable of dithering

A laser cladding method for depositing a cladding layer on a workpiece having a three-dimensional surface, the method comprising:

• generating a laser beam from a fiber laser and collimating the laser beam by passing the laser beam through collimating optics to provide a collimated laser beam defining a Z axis along a length of the collimated beam, the collimated laser beam having a consistent Z axis power density along at least a portion of a length of the collimated laser beam;
• directing the collimated laser beam toward the workpiece to provide a beam spot on a surface of the workpiece;
• dithering the collimated laser beam along at least one of X and Y axes perpendicular to the Z axis defined by the collimated laser beam such that the beam spot is dithered on the workpiece as the workpiece is moved, wherein dithering the collimated laser beam includes moving a fiber laser output without moving the collimating optics, wherein dithering is performed within a range of ±10 mm;
• directing a cladding material toward the workpiece such that the cladding material impinges the surface of the workpiece on a region heated by the beam spot, wherein the collimated laser beam is directed to the surface of the workpiece in advance of the cladding material, and wherein the collimated laser beam provides the consistent Z axis power density at different processing locations on the three-dimensional surface of the workpiece to provide a consistent temperature profile on the surface of the workpiece in advance of the cladding material, wherein the collimated laser beam has the consistent Z axis power density along a working range along the Z axis of at least 300 mm;
• and
• moving the workpiece such that the cladding material forms a cladding layer on the surface of the workpiece as the workpiece moves.