To optimize the process parameters of a non-uniform Fe45 powder laser cladding process， a 3-kW robot laser cladding system was used for the working process test. A 4-factor 3-level L₉（4³） orthogonal test plan was designed according to the reference range of the process parameters of the cladding system， and the effects of each process parameter on the surface morphology， internal defects， and dilution rate of the single-pass cladding layer were discussed by using the extreme value R analysis. Furthermore， the optimized parameters corresponding to the individual targets were also analyzed. Thereafter， the comprehensive optimal cladding process parameter combination was found through a multi-objective fuzzy comprehensive evaluation method. Finally， the effect of overlap rate （30%， 40%， and 50%） on surface morphology and internal quality of the multi-layer cladding were studied. The results show that the influence of the process parameters on the morphology of the cladding layer from large to small is scanning speed （B）， laser power （A）， defocusing amount （D）， and powder feeding speed （C）， and the optimal parameter is A₃B₂CD₂； the influence of the process parameters on the defects of the cladding layer from large to small is scanning speed or defocusing amount， laser power， and power feeding speed， and the optimal parameter is A₃B₁C₂D₂； the influence of the process parameters on the dilution rate from large to small is powder feeding speed， defocusing amount， laser power and scanning speed， and the optimal parameter is A₁B₁C₃D₂. The optimal parameters for the comprehensive process are as follows： laser power is 2400 W， scanning speed is 5 mm/s， powder feeding speed is 20 g/min， and focal length is +5 mm. We could achieve a dense cladding structure with a continuous surface and no internal defects when cladding at different overlap rates with the optimized process parameters， and the laser cladding exhibited the best effect at the overlap rate （η） of 40%.