Abstract: In order to study the influence of process parameters on crack and thickness of Ni60 laser cladding, the orthogonal experiment was designed by laser cladding Ni60 powder on the surface of 45^# steel. The primary and secondary factors affecting the crack formation and coating thickness were analyzed, then, the range analysis method was carried out to obtain the optimal process parameters with the least cracks.The result showesthat the affecting order of crack is that scanning speed > powder feeding rate > laser power; and the process parameters with the least cracks areas follows: Laser power is 1400W, scanning speed is 4.0mm/s, powder feeding rate is 1.0r/min, and thereis only a short crack at the initial position of cladding by using the process parameter. The order of influence on coating thickness is as follows: powder feeding rate > scanning speed. Through microhardness test, the hardness of cladding layer is 3.3 times of that of substrate. Through scanning electron microscope analysis, the grain structure of cladding layer is uniform, and a good metallurgical combination with substrateis formed, which provided a reference for the engineering application of Ni60 alloy powder laser cladding.