• Laser power and scanning speed are the most influential parameters affecting clad geometry and dilution.
• The optimized parameters (1.8 kW, 6 mm/s, 12 g/min) yield a dilution of 8.5% and microhardness of 650 HV.
• Response surface methodology effectively models and optimizes laser cladding process parameters.
• The Ni-based coating exhibits uniform microstructure and strong metallurgical bonding, enhancing surface properties.