{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,8,18]],"date-time":"2026-08-18T04:54:18Z","timestamp":1787028858488,"version":"build-2736575974"},"reference-count":274,"publisher":"MDPI AG","issue":"22","license":[{"start":{"date-parts":[[2025,11,19]],"date-time":"2025-11-19T00:00:00Z","timestamp":1763510400000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Materials"],"abstract":"<jats:p>Metals with a hexagonal close-packed (HCP) structure such as magnesium, titanium and zirconium constitute key structural materials in the aerospace, automotive, biomedical and nuclear energy industries. Their welding and regeneration by conventional methods is hindered due to the limited number of slip systems, high reactivity and susceptibility to the formation of defects. Laser technologies offer precise energy control, minimization of the heat-affected zone and the possibility of producing joints and coatings of high quality. This article constitutes a comprehensive review of the state of knowledge concerning laser welding, cladding and regeneration of HCP metals. The physical mechanisms of laser beam interactions are discussed including the dynamics of the keyhole channel, Marangoni flows and the formation of gas defects. The characteristics of the microstructure of joints are presented including the formation of \u03b1\u2032 martensite in titanium, phase segregation in magnesium and hydride formation in zirconium. Particular attention is devoted to residual stresses, techniques of cladding protective coatings for nuclear energy with Accident Tolerant Fuel (ATF) and advanced numerical modeling using artificial intelligence. The perspectives for the development of technology are indicated including the concept of the digital twin and intelligent real-time process control systems.<\/jats:p>","DOI":"10.3390\/ma18225237","type":"journal-article","created":{"date-parts":[[2025,11,19]],"date-time":"2025-11-19T15:03:15Z","timestamp":1763564595000},"page":"5237","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":3,"title":["Laser Technologies of Welding, Surfacing and Regeneration of Metals with HCP Structure (Mg, Ti, Zr): State of the Art, Challenges and Prospects"],"prefix":"10.3390","volume":"18","author":[{"ORCID":"https:\/\/orcid.org\/0000-0003-1631-2319","authenticated-orcid":false,"given":"Adam","family":"Zwoli\u0144ski","sequence":"first","affiliation":[{"name":"Faculty of Mechanical Engineering, Lublin University of Technology, Nadbystrzycka St. 36, 20-618 Lublin, Poland"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-3524-3200","authenticated-orcid":false,"given":"Sylwester","family":"Samborski","sequence":"additional","affiliation":[{"name":"Faculty of Mechanical Engineering, Lublin University of Technology, Nadbystrzycka St. 36, 20-618 Lublin, Poland"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0003-3942-337X","authenticated-orcid":false,"given":"Jakub","family":"Rzeczkowski","sequence":"additional","affiliation":[{"name":"Faculty of Mechanical Engineering, Lublin University of Technology, Nadbystrzycka St. 36, 20-618 Lublin, Poland"}],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"1968","published-online":{"date-parts":[[2025,11,19]]},"reference":[{"key":"ref_1","doi-asserted-by":"crossref","first-page":"188","DOI":"10.1016\/j.jmatprotec.2005.06.068","article-title":"A Review of Laser Welding Techniques for Magnesium Alloys","volume":"171","author":"Cao","year":"2006","journal-title":"J. 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