<p>This study aims to model and explore the effect of major variables of the laser cladding process including laser power (<i>P</i>), laser scanning speed (<i>S</i>), and powder feed rate (<i>F</i>) on the single-track geometry of Stellite 6 cobalt-based alloy applied on Steel AISI 5046. For this purpose, substrates of GM locomotive crankshaft alloy were covered with Stellite 6 cobalt-based powder through a laser cladding process. To evaluate the geometric, microstructural, elemental, and phase characteristics, optical microscope, field emission scanning electron microscopy, energy-dispersive spectroscopy, and x-ray diffraction were used, respectively. Statistical models revealed that single-track dimensions are determined by the interplay of laser power, scanning speed, and feed rate, specifically through complex variable combinations. The results indicated that the height, width, penetration depth, dilution, and wettability angle of the single-track layers are controlled as <i>P</i>^4/5<i>S</i>^−5/4<i>F</i>^1/2, <i>P</i>^6/10<i>S</i>^−2/10_, <i>P</i>⁴<i>S</i>^−3/7<i>F</i>^−6/7, <i>P</i>⁴<i>F</i>^−6/5, and <i>P</i>^4/5<i>S</i>^−5/4<i>F</i>^1/2, respectively. Based on these experimental relations, the map of process variables was obtained for predicting the single-track geometry and as a guide for selecting suitable parameter levels in the laser cladding process of Stellite 6 on locomotive crankshaft alloy. Based on the geometric properties of the laser clad of interest, this map can be used for selecting the process variables. The microstructural and phase characterizations indicated that the clad layer is the form of cobalt γ solid solution with planar and cellular crystallization structures close to the interface, columnar dendritic structure in the central region, and coaxial dendritic structure across the clad surface.</p>