Field demonstrations of laser cladding technology hosted by the University of Sheffield Rail Group have shown how additive manufacturing can repair railway infrastructure and provide superior wear resistance.
Working in collaboration with British Steel and Technogenia UK – Laser Cladding Technology Ltd, the researchers are using laser cladding to repair railway track steel, a development that could make rail repairs faster and more cost effective. The work reveals important advances in a technique that allows worn or damaged components to be repaired, rather than replaced outright.
The group say they are pioneering the transition of advanced laser cladding technology from the lab to the track, verifying its capability to deliver durable, enhancements and rail repairs.
This latest field testing in Scunthorpe picks up the results from successful laboratory trials and takes them into the real world of rail repair and maintenance.
It follows two key milestones: the May 2023 installation of laser-clad sections to demonstrate wear resistance, and the August 2025 installation of a test segment specifically focused on the in-situ repair of existing rail.
Both installations have been regularly monitored (with non-destructive techniques) to precisely capture changes in rail profile, surface roughness, and hardness.
Industry partners were invited to British Steel to view the field tests firsthand and engage in productive discussions regarding the next steps for application and implementation within the rail industry.
Dr Kate Tomlinson, Lecturer in Tribology, said: “Our research demonstrates that laser cladding is a highly promising alternative for rail repair. It can be used for rail life extension and to restore damaged sections, offering a more cost effective and sustainable approach than total rail replacement. The initiatives we are developing at Sheffield are essential in providing the technical confidence required for the future of maintaining the UK rail network.”
More information, plus a new video, about the project can be found on the field test validation webpage.
