To predict the geometric characteristics and improve the forming quality and macro-micro defects of multi-track overlapping cladding layer effectively, the experimental research of laser melting deposition single-track Co-based alloy on 42CrMo substrate was carried out. The influence trends of laser process parameters on the single-track cladding height and cladding width were analyzed, and the regression prediction models were established. A variable-process alternated overlapping strategy was proposed using the geometric functions to fit the single-track profile. The surface forming quality and macro-micro defect of different overlapping cladding layers were compared and evaluated. The results showed that the cladding height and cladding width regression models established by an improved optimization algorithm had an excellent prediction effect. The variable-process alternated overlapping cladding layer prepared by the parabolic function had a flat surface, and the fluctuation distance was 81.56 μm, which was significantly improved compared with other overlapping strategies. The surface flatness of the continuous overlapping cladding layer was the worst and the spheroidization defect was the most unsatisfied. The internal defects of the constant-process alternated overlapping cladding layer were the most terrible, with more non-fusion and cracks caused by oxides. The variable-process alternated overlapping strategy proposed in this study can effectively prepare a multi-track cladding layer with a smooth surface and dense interior, which provides essential theoretical guidance for the near-net forming of component surface deposition and repair.
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