Robotically-controlled laser cladding process for repair of worn and/or damaged railway structures

A method of repairing a worn railway structure comprising the steps of:

• providing a metal railway structure comprising a surface;
• providing a laser system having a first laser beam having a first laser energy having a specific structured beam shape;
• removing a plurality of layers of metal from a location of the surface of the railway structure with the first laser beam to form a prepared surface having a depth from the surface of the metal railway structure, the depth formed by the first laser beam;
• and
• depositing metal material onto the location of the prepared surface using a second laser beam from the laser system and a deposition material combined with the second laser beam to form a finished surface of the railway structure,
• wherein the temperature of the railway structure is maintained below 500° F. during metal removal from the railway structure with the first laser beam and metal deposition to the railway structure with the second laser beam.