The growing demand for high-performance components in sectors such as aerospace, medical devices, and micro-motors has accelerated advancements in additive manufacturing (AM) techniques. Among these, laser cladding has proven to be an effective method for producing durable, high-quality coatings with tailored properties that meet specific operational requirements. This study focuses on tungsten carbide (WC)-reinforced nickel-based metal-matrix composites (MMCs), which are widely valued for their outstanding hardness, wear resistance, and thermal stability. However, challenges such as thermal cracking, porosity, and residual stresses—caused by thermal expansion mismatches between WC particles and the Ni-based matrix—continue to hinder their broader application, particularly in complex geometries. To mitigate these challenges, various strategies have been explored, including process parameter optimization, powder composition modifications, and advanced methods such as electromagnetic field application and ultrasonic vibration during cladding. Recent progress in computational modeling, particularly phase-field fracture models, has provided a deeper understanding of thermal cracking and defect formation in MMC coatings. These models offer detailed insights into crack initiation, propagation, and the influence of process parameters on microstructure evolution and mechanical properties. This study integrates a fully coupled phase-field fracture model with thermomechanical analysis to investigate the laser cladding of WC–NiCrBSiFe coatings. The analysis examines the thermal history, cladding morphology, and real-time crack formation during solidification, providing insights into the interplay between WC content, hardness, toughness, and hot cracking susceptibility. The results indicate that an optimal WC content of approximately 30 wt% leads to coatings with excellent hardness and wear resistance while minimizing defect formation. However, exceeding this threshold increases brittleness, which contributes to higher residual stresses and an elevated risk of hot cracking. By offering valuable insights into defect reduction and process parameter optimization, this study contributes to the development of more reliable and high-performance WC-based coatings. These findings support the production of durable components for demanding industrial applications. Through advancements in computational modeling and laser cladding methodologies, this work plays a key role in the