Tribological response of laser-textured Ti6Al4V under fretting conditions: An analysis of texture-induced wear regime transition

This study presents a mechanistic investigation into the fretting wear behavior of Ti6Al4V alloy with grid-like laser surface textures, focusing on the interplay among texture geometry, debris behavior, and subsurface deformation. Fretting tests were conducted in a ball-on-flat configuration under loads of 20–100 N. Results show that texture-induced modifications of debris dynamics and stress distribution govern the fretting response in both gross and partial slip regimes. In gross slip, dense and deep textures exacerbate adhesive wear by entrapping debris and reducing its protective role, thereby increasing the coefficient of friction. Under partial slip, the same textures facilitate plastic flow and micro-crack initiation at groove edges, leading to layered material separation and early stabilization of slip. Pit filling mechanisms are shown to be orientation-dependent: perpendicular grooves experience crack propagation and lamellar fracture, while parallel grooves exhibit gradual material flow resulting in coherent filler layers. System deformation measurements and SEM analysis further correlate texture parameters with localized damage modes. These findings provide deeper mechanistic insight into how surface texturing influences fretting wear processes in titanium alloys, offering a foundation for texture optimization based on tribological regime and microstructural response.