To address the issue of powder surge in laser cladding carrier gas transportation, a comprehensive simulation analysis was conducted focusing on four key parameters: lifting angle, bending radius, lifting height, and gas flow rate. The study aimed to elucidate the underlying causes of powder surge. The discrete element method (DEM) is used to solve the motion and force of discrete particles, and the computational fluid dynamics (CFD) is used to solve the continuous phase flow field, which is coupled with each other to form a discrete element-computational fluid dynamics (DEM-CFD) model. The simulation results show that the phenomenon of wheezing powder is caused by the position distribution of particles flowing through the elbow. The particles outside the elbow maintain this state until they diffuse in the vertical pipe section, and the particles inside and in the middle of the elbow constantly collide with the wall surface, which leads to different movement time of particles in the elbow section, resulting in a sharp increase in powder amount in a certain period of time. The influencing factors of powder surge are gas flow rate, lifting height, bending radius and lifting angle from large to small. In order to ensure the continuous and stable transportation process, the air flow rate should be greater than 6 L/min, and the transportation should be carried at 45° lifting angle under the condition of meeting the transportation conditions, and the bending radius should be reduced and the lifting height should not be higher than 2.5 m.