Abstract: Objective The aim is to solve problem of poor adaptability of pre-placed powder and lack of experimental data in conventional tunsten inert gas (TIG) cladding. Methods This paper designed and fabricated tubular and annular coaxial powder-feeding TIG guns. A three-dimensional numerical model was established to compare arc morphology, flow field and powder utilization rate, followed by process experiments in which welding heat input, powder-feeding rate and SiC concentration were varied to produce and evaluate cladding layers. Results The results showed that annular coaxial powder-feeding maintained a complete “bell-shaped” arc, eliminated annular vortices and achieved significantly higher powder utilization rate than tubular structure. Process trials revealed that tubular powder-feeding cladding layers had pits at arc extinguishing position, non-straight welds and uneven weld width, whereas the annular powder-feeding cladding layers presented a smooth surface, uniform geometry and higher cladding efficiency. Conclusion Annular coaxial powder-feeding TIG cladding is better than tubular configuration in arc stability, powder utilization rate and forming quality, making it more suitable for high-efficiency surface-repair applications.