The objective of this paper is to introduce large area heat treating and cladding processes using novel, free space diode lasers as a means to reduce re-manufacturing costs and extend field lifetime of components. Lasers have been explored as an option for hard-facing and repair of metal surfaces for several years. This paper will describe how recent advances in diode laser design have resulted in enhanced process yields, improved quality and increased throughput, while also minimizing operating cost. A quantitative study shows that the time needed to cover a one square meter area during heat treating, and also during cladding applications, decreases by a factor of approximately 2.5, even when the laser power has only been increased by a factor of 1.75. This assumes the line beam length has also been increased to take full advantage of the additional laser power.