Effect of Surface Roughness on High-temperature Fretting Wear Behavior and Mechanisms of FGH99 Powder Superalloy

HE Xiangping; KONG Weiyu; WANG Zidan; YAN Ying; BAI Qian

doi:10.16490/j.cnki.issn.1001-3660.2026.17.013

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Surface Technology ›› 2026, Vol. 55 ›› Issue (17) : 158-165. DOI: 10.16490/j.cnki.issn.1001-3660.2026.17.013

Friction, Wear and Lubrication

Effect of Surface Roughness on High-temperature Fretting Wear Behavior and Mechanisms of FGH99 Powder Superalloy

HE Xiangping, KONG Weiyu, WANG Zidan, YAN Ying, BAI Qian^*

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Abstract

Aero-engine turbine disk tenon/mortise joints operate under extreme high-temperature and high-vibration conditions, making them highly susceptible to severe fretting degradation. To address this critical issue, the work aims to systematically investigate the profound effect of grinding-induced surface roughness on the high-temperature fretting wear performance and underlying damage mechanisms of the FGH99 powder metallurgy nickel-based superalloy, ultimately seeking to provide a solid theoretical basis and practical engineering guidance for optimizing surface integrity manufacturing processes and significantly improving the fretting fatigue life of aero-engine tenon/mortise structures. Cubic boron nitride (CBN) grinding wheels were employed to perform surface grinding on FGH99 superalloy specimens. While processing parameters such as wheel linear speed, feed rate, and grinding depth were kept consistent, specimens with varying surface roughness were prepared by sequentially changing the grinding wheels of different grit sizes (60#, 240#, 400#, and 600#). Simultaneously, lapped and polished specimens were prepared as a control group. Fretting wear tests were conducted with a high-temperature fretting wear tester. Advanced characterization techniques, including a 3D white-light interferometer, scanning electron microscope (SEM), and energy-dispersive X-ray spectroscopy (EDS), were utilized to conduct multi-scale systematic characterization on the dynamic friction coefficient evolution, 3D wear scar morphology, wear volume, as well as the subsurface damage layer and cross-sectional wear scars in the contact zone of specimens with different surface roughness levels. This was done to deeply analyze the micro-regulation mechanism of surface roughness on the high-temperature fretting wear resistance of the FGH99 superalloy. The results indicated that the alteration of surface roughness fundamentally regulated the distribution state of interfacial contact stress and the evolution behavior of wear debris, leading to different dominant fretting wear mechanisms for surfaces with varying roughness. For the low-roughness polished surface (S_a=0.02 μm), due to the relatively smooth interface, the real contact area increased, making it highly susceptible to severe metal adhesion at a high temperature of 750 ℃. Moreover, the nascent wear debris was difficult to discharge, and the dominant wear mechanisms were characterized by adhesive wear and oxidative wear. For specimens with moderate surface roughness (S_a=0.10 μm), the moderate microscopic valley morphology could effectively capture the free oxide debris. Under continuous high-temperature cyclic extrusion, this promoted the refinement, compaction, and high-temperature sintering of the debris, ultimately forming a dense glaze layer with high load-bearing capacity in the contact zone. This wear mechanism was dominated by a protective third-body layer, effectively isolating the direct contact between the metal matrices. Conversely, for specimens with high surface roughness (S_a=1.10 μm), the coarse asperities led to extreme stress concentration at the contact points. These asperities were highly prone to fracture under cyclic shear forces, generating large-particle hard abrasives. The wear mechanism was mainly manifested as a synergistic effect of severe abrasive wear and subsurface fatigue wear. This work fully confirms that optimizing the grinding process to obtain a moderate surface roughness is a key approach to promoting the formation of a high-temperature protective glaze layer and effectively inhibiting the fretting damage of the FGH99 superalloy.

Key words

surface roughness / high-temperature fretting wear / wear mechanism / FGH99 superalloy / grinding

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HE Xiangping, KONG Weiyu, WANG Zidan, YAN Ying, BAI Qian. Effect of Surface Roughness on High-temperature Fretting Wear Behavior and Mechanisms of FGH99 Powder Superalloy[J]. Surface Technology. 2026, 55(17): 158-165

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