Laser cladding fabrication method

A method of fabricating a bushing, comprising:

• generating a laser beam at a first angle relative to an end surface of the bushing to produce a first laser beam spot having a generally circular or square shape;
• feeding a cladding material into the first laser beam spot to produce a cladding layer within a circumferential groove in the end surface, the circumferential groove having a width greater than a first dimension of the first laser beam spot;
• generating a laser beam at a shallower second angle relative to the end surface of the bushing to produce a second laser beam spot having a generally elliptical or rectangular shape and a second dimension about equal to the width of the circumferential groove;
• and
• moving the second laser beam spot along the cladding layer to substantially flatten the cladding layer within the circumferential groove.

A laser cladding system, comprising:

• a fixture configured to hold a component;
• a material feeder configured to direct a cladding material toward a wear surface of the component when the component is held in the fixture;
• a laser configured to direct a laser beam onto the wear surface of the component when the component is held in the fixture;
• and
• a controller in communication with the laser and the material feeder, the controller being configured to:
• generate a laser beam at a first orientation to produce a first laser beam spot having a first characteristic;
• cause the material feeder to direct the cladding material into the first laser beam spot to produce a cladding layer on the wear surface;
• generate a laser beam at a second orientation to produce a second laser beam spot having a second characteristic;
• and
• move the second laser beam spot along the cladding layer to substantially flatten the cladding layer.