Abstract: An improved process for repair of worn and damaged surfaces of railway structures such as frog and diamond transition surfaces, rail head surfaces and wheels. A worn or damaged surface is prepared using a robotically-controlled laser to melt or gouge away metal using controlled laser energy and air pressure to remove existing worn or damaged surfaces. The process further utilizes laser cladding, laser weld overlaying, or laser additive manufacturing, of formulated powder, wire or stick welding material to worn surfaces that have been prepared for material build-up to original dimensions and similar metallurgical properties.

Abstract: A material processing system for a base material is provided. The system includes a feeder having a distal end proximate to a surface location of the base material. The feeder supplies a deposit material to the surface location. The deposit material has a width having a first side and a second side. A first laser is directed to the deposit material at the surface location. The first laser is directed across the width from the first side to the second side. A second laser is directed to a desired location within the width. A control system drives the process of cladding the deposit material. The control system includes a shape controller to control the movement of the secondary laser along the deposit material based on feedback from a sensor.