A Novel Approach to Improve the Fretting Fatigue Resistance of Coating‐Substrate Systems by Laser Surface Texturing

ABSTRACT Laser surface texturing (LST) is a promising approach for enhancing the interfacial strength and durability of coating‐substrate systems. In this study, laser‐textured dimples are introduced into the coating‐substrate system to investigate the influence of geometric parameters on interfacial strength and fatigue damage under fretting conditions. Three dimensionless parameters ( λ , η , and ξ ) representing the texture dimple depth, density and distance from the contact center to the nearest dimple on the surface, respectively, are defined to determine the optimal texture. Simultaneously, the Smith‐Watson‐Topper (SWT) parameter and the stress sharp change value (SCV) are employed to quantify fatigue damage and interfacial strength, respectively. Through a combination of theoretical analysis and finite element method, an optimal dimple geometric configuration ( λ = 0.5 and η = 1) is identified, which mitigates fretting contact damage without inducing severe local stress concentrations within the texture itself. Furthermore, a width‐dependent optimal distance range (1.0 ≤ ξ ≤ 1.3) is determined to achieve a “damage equilibrium” state, where the maximum fatigue damage is reduced by 11.2%. Finally, the optimal texture reduces the SCV of von Mises stress by 20.6%, significantly improving the interfacial strength. These findings offer an important theoretical basis for the practical application of LST in anti‐fretting fatigue design of coating‐substrate systems.