Solid-State Additive Cladding & Hardfacing

Rotary Friction Surfacing (RFS) Cladding Calculator

Calculate consumable rod plasticization rates, single-pass deposit thickness, frictional heat input, and multi-track overlap stepover pitches for solid-state repair, corrosion-resistant cladding, and additive manufacturing.

Process Parameters & Inputs

Consumable Rod Diameter (D_rod):

Diameter of rotating consumable alloy rod in mm.

Spindle Rotation Speed (N_rpm):

Consumable tool spindle speed in RPM.

Axial Plunge Force (F_z):

Hydraulic or servo axial downward thrust force in kilonewtons (kN).

Traverse Table Speed (v_x):

Linear traverse speed along substrate in mm/s.

Multi-Track Overlap Ratio:

Stepover overlap percentage between adjacent deposit passes.

Calculated Engineering Metrics

Clad Layer Thickness

1.85mm

Deposit Bead Width

24.2mm

Frictional Heat Input

5.8kW

CAM Stepover Pitch

15.7mm

Toolpath & Geometry Simulation

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Engineering Principles & Formula Reference

Rotary Friction Surfacing (RFS) deposits solid-state metallic coatings without bulk melting. Severe plastic deformation and frictional heating generate a dynamic recrystallized boundary layer that shears onto the substrate.

Clad Thickness & Thermal Heat Generation:

t_{clad} = \frac{\pi R_{rod}^2 \cdot v_{burn}}{W_{bead} \cdot v_x}
q_{fric} = \frac{2}{3} \pi \mu F_z N R_{rod}
S_{stepover} = W_{bead} \cdot \left(1 - \frac{\text{Overlap}\%}{100}\right)

Because melting is avoided, RFS eliminates porosity, hot cracking, and brittle intermetallic phases when joining dissimilar alloys (e.g., aluminum to steel or Inconel to carbon steel).