Field test validation: Additively manufactured laser cladding for rail

Field test validation has recently been completed for our additively manufactured rail enhancement offering wear reduction and damage repair with laser cladding technology. The technology has been developed over multiple projects - find out more from our video and the links below.

Field testing of additive manufacture of laser clad coatings for rail life extension

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From lab to field testing

The University of Sheffield's railway research team, in collaboration with industry partners British Steel and Technogenia UK - Laser Cladding Technology Ltd, is pioneering the transition of advanced laser cladding technology from the lab to the track, verifying its capability to deliver durable, enhancements and rail repairs.

The field test validation bridges the gap between laboratory success and real-world adoption of laser cladding for rail repair. The initial field test includes laser clad rail sections which were installed in May 2023 at British Steel track, used to test and compare performance of sleeper types, in Scunthorpe. This field test includes multiple test segments using different materials, such as MSS and Stellite 6 clad layers, alongside standard and premium rail materials, to test life extension applications. A specific focus of this field trial is the unique capability of the laser cladding to reduce lipping at insulated block joints (IBJs). A structured monitoring regime is in place, utilising non-destructive techniques to precisely capture changes in rail profile, surface roughness, and hardness, ensuring a comprehensive assessment of the technology's performance under in-service conditions.

A subsequent field test segment, installed in August 2025, focuses specifically on validating the refurbishment application of laser cladding, which utilises a different approach: repairing existing rail sections with like-on-like materials. The test piece is an R260 rail repaired with R260 grade metal powder at a 3 mm depth. This installation is being closely monitored to assess the structural integrity and long-term wear performance of the 'like-on-like' repair under operational conditions, validating the pathway for this technique to be translated into future in-situ mobile maintenance applications.

Background information

More information on the laser cladding additive manufacturing process and its performance for rail applications can be found in the papers linked below.

Scaling-up laser cladding of rails - White Rose Research Online
Evaluation of laser cladding as an in-situ repair method on rail steel
Laser cladding of rail; the effects of depositing material on lower rail grades
Full-scale testing of laser clad railway track; Case study – Testing for wear, bend fatigue and insulated block joint lipping integrity
Improving rail wear and RCF performance using laser cladding
Assessment of laser cladding as an option for repairing/enhancing rails