Cassette biting into freehub

I bought some new wheels at the end of last year and I was doing some maintenance on the bike a few weeks ago and noticed that the rear wasn’t spinning as freely as I’d have expected. I took it off and spun it in my hands and it still wasn’t spinning so I decided to take the rear cassette off and see if I could figure out what the problem is.

After releasing the locking nut the first few cassette rings came off the hub without any trouble but then I couldn’t get any more off. Whilst I haven’t been to the gym recently I didn’t think that my strength had abandoned me entirely so I had a good look and realised that the rings had ‘bitten’ through the splines on the freehub and locked itself in place.

I managed to unlock it with a chain whip and noticed it had managed to cut almost entirely through the spline. I managed to take the rest of the cassette rings off and most of these had also bitten through the hub to a lesser degree.

Once I’d managed to take the cassette off there was nothing obviously hindering the hub’s movement but it still won’t spin freely and is really stiff.

I sent the wheel back to the guys that built it and their response was that the preload tensioner was set too high.

However they also said that any cassette (with the exception of SRAM Red) will have a tendency to bit through an allow freehub. I’ve never seen this before and find it hard to believe that I need to spend ~£230 on a rear cassette to stop this problem happening again.

Has anyone else had a similar problem?