Laser cladding downhole repair

A system for repairing a tubular disposed in a wellbore, the system comprising:

• a downhole repair tool comprising:
• a main body assembly configured to be positioned within the tubular;
• a cladding feed assembly configured to dispose a cladding material on an interior surface of the tubular;
• and
• a laser head assembly comprising a laser head configured to direct a laser beam radially outward with respect to a central axis of the tool towards the defect area to thereby weld at least a portion of the cladding material to the interior surface at the defect area, the laser head assembly articulated to positionally adjust the laser head radially with respect to the central axis independently of the position of the tool to thereby adjust the distance between the laser head and the defect area while the tool and the laser head otherwise remain substantially motionless relative to the defect area, thereby selectively adjusting the area of incidence of the laser beam on the cladding material at the defect area;
• and
• a conveyance configured to lower the repair tool downhole to a position proximate the defect area.

A method for repairing a tubular disposed in a wellbore, the method comprising:

• lowering, by a conveyance assembly, a downhole repair tool within the tubular to a defect area on an interior surface of the tubular, the downhole repair tool comprising:
• a main body assembly configured to be positioned within the tubular;
• a cladding feed assembly configured to dispose a cladding material at the defect area;
• and
• a laser head assembly comprising a laser head configured to direct a laser beam radially outward with respect to a central axis of the tool and articulated to positionally adjust the laser head radially with respect to the central axis independently of the position of the tool;
• disposing from the cladding feed assembly the cladding material onto the defect area;
• transmitting, as a first instance of laser beam transmittal with the laser head assembly in a first adjustment state, a laser beam from the laser head assembly onto the cladding material at the defect area, thereby welding at least a first portion of the cladding material in the defect area;
• and
• positionally adjusting the laser head radially with respect to the central axis independently of the position of the tool to a second adjustment state, thereby adjusting the distance between the laser head and the defect area while the tool and the laser head otherwise remain substantially motionless relative to the defect area;
• transmitting, as a second instance of laser beam transmittal with the laser head assembly in the second adjustment state, the laser beam from the laser beam assembly onto the cladding material, thereby welding at least a second portion of the cladding material in the area to the interior surface of the tubular, wherein, in the second adjustment state, an area of incidence of the laser beam incident on the cladding material at the defect area is larger than in the first adjustment state.