Rotary Friction Surfacing (RFS) Prepress CAM Vector Guide

Master solid-state cladding calculations, stepover overlaps, and multi-track CAM vectorization.

1. Solid-State Rotary Friction Surfacing (RFS) Overview

Rotary Friction Surfacing (RFS) is a thermo-mechanical solid-state cladding process where a rotating metallic consumable bar is pressed against a substrate under heavy axial thrust. Frictional heating plasticizes the rod tip, which is sheared and transferred onto the substrate without melting.

2. Deposit Microstructure & Dissimilar Metal Bonding

Because the peak temperature remains below the solidus melting point ($T_{peak} \approx 0.7 - 0.85 T_{melt}$), dilution with the substrate is near zero ($< 1\%$). RFS enables defect-free joining of metallurgical incompatibles:

• Aluminum Cladding on Steel: Eliminates brittle $FeAl_3$ and $Fe_2Al_5$ intermetallic phases that cause cracking in fusion welding.
• Stellite & Superalloys on Carbon Steels: Retains high hardness without weld-dilution softening.
• Corrosion Barriers: Fully dense, void-free austenitic stainless steel overlays on marine drive shafts.

3. Operating Parameters for Common Alloys

4. Prepress CAM Vector Planning for Multi-Pass Overlays

• Serpentine Overlap Stepover: Maintain $30\% - 45\%$ bead overlap to ensure uniform surface height and eliminate inter-pass valleys.
• Lead-In & Flash Run-Off Tabs: Program $15\text{ mm}$ entry and exit run-off vectors to keep consumable rod plasticization transients off the finished component.
• SpotItLive Vector Studio CAM Export: Generate continuous serpentine raster and spiral toolpath DXF vectors tailored for multi-axis CNC machine tools and robotic friction stir platforms.