Friction Surfacing is a process derived from friction welding whereby a coating material, in rod form (termed the MechtrodeTM) is rotated under pressure, generating a plasticised layer in the rod at the interface with the substrate. By moving a substrate across the face of the rotating rod a plasticised layer between 0.2-2.5mm thick is deposited (depending on mechtrode diameter and coating material). The resulting composite material is created to provide the characteristics demanded by any given application.

During the coating process, the applied layer of metal reaches a temperature near the melting point whilst simultaneously undergoing plastic deformation. The coating is thus the product of a hot forging action, as opposed to the casting mechanism inherent in welding and spraying processes. This important difference means that many of the defects commonly associated with these techniques are avoided.