Fretting Wear Tests Research Articles

Contact geometry and contact time effect on 690TT alloy/405 stainless steel impact-sliding fretting wear processes

Due to the inevitable flow-induced vibration and turbulent excitation in steam generator (SG), it is impossible to avoid fretting wear or impact between steam generator tubes (SGTs) and anti-vibration bars (AVBs). Therefore, the approach of this work was to simulate the real fretting problems between SGTs and AVBs. Thus, the impact-sliding fretting wear tests of 690TT alloy/405 stainless steel (405 SS) were investigated under various contact times in tube/plate configuration and tube/cylinder configuration in air at room temperature, respectively. The results indicated that the influences of contact geometry and contact time on the peak radial force (Frp) were insignificant, while the value of peak tangential force (Ftp) was seen to increase with increasing contact time and was associated with the contribution of sliding wear to impact-sliding process. Meanwhile, the degree of wear damage increased with the increase of contact time, either line contact or point contact. The damage area of wear scar in tube/plate configuration was evidently larger than that of tube/cylinder configuration. Instead, the maximum wear depth of tube/cylinder configuration was larger than that of tube/plate configuration. Along the sliding direction, the “U" shape profiles were usually detected whether tube/plate configuration or tube/cylinder configuration. In general, both contact geometry and contact time had a direct influence on the behavior of wear debris, i.e., movement and oxidation.

MoS2/Ti Co-deposited Coatings and Their Fretting Wear Properties at Elevated Temperatures

Abstract Fretting wear refers to the damage phenomenon experienced by the mechanical components undergoing micro-amplitude relative slip at their contact region due to vibration. Titanium alloys find their extensive application in aerospace industry components such as splines and dovetail joints, where they experience fretting wear phenomenon. This research work investigates the effect of MoS2/Ti co-deposition coatings with varying Ti content, deposited on TC4 titanium alloy substrate using magnetron sputtering. Fretting wear tests were conducted at room temperature, 100 °C, and 200 °C, using a specially designed fretting test fixture with a ball-on-flat contact configuration, mounted on a servo-hydraulic fatigue testing machine. The results indicated that the coating becomes denser with an increase in the Ti content. The coating exhibited the highest hardness and better anti-fretting wear performance at room temperature. However, the effect of Ti content on the fretting wear behaviors changed at elevated temperatures. At the highest Ti content coating, excessive oxide particles were found at the worn surface at elevated temperatures, inducing an abrasive effect and localized cracks. However, coatings with moderate Ti content (9.62 at. %) effectively protected the substrate from significant wear at room temperature and maintained a low coefficient of friction at high temperatures without failure.

Effect of torsional angle on the fretting wear behavior and fracture failure mechanism of steel wires with spiral contact structure

The fretting wear of steel wire will reduce the service life of wire rope and severely threaten the safety of mine hoisting. To investigate the influence of torsion on the fretting wear behavior of steel wire, the fretting wear tests of steel wires with spiral contact structure under the action of tensile-torsional coupling forces were conducted, and the fatigue fracture failure mechanism was revealed. The result indicates that the CoF increases with increasing torsional angle. As the cycles increase, the sliding distance between the wires decreases, while the adhesion increases. The fretting area gradually transitions from gross sliding status to partial sliding status. The sliding distance and energy loss between the wires increase with increasing torsional angle. The wear depth and coefficient increase with increasing torsional angle, and the wear level of peak contact structure is more serious than that of valley contact structure. The primary wear mechanisms of steel wire are abrasive wear, adhesive wear and fatigue wear. The fatigue fractograph of steel wire is obviously divided into fatigue source zone, crack growth zone and final fracture zone. Abundant secondary cracks and dimples exist in the final fracture zone, and the fatigue fracture failure mechanism is mainly ductile fracture.

Effect of external magnetic field on the fretting wear mechanism of the ferromagnetic materials

With the widespread implementation of maglev technology in fields such as rail transit and military, it is imperative to investigate the effects of magnetic fields on fretting damage in metallic materials. This study conducted multi-parameter fretting wear tests on typical ferromagnetic counterparts in the presence of an external permanent magnetic field. Subsequently, the wear behavior and damage mechanism of the fretting interface were elucidated through multi-scale characterization analysis. The results indicated that the operation state of the fretting interface was shifted towards the partial slip regime under the magnetic field. Meanwhile, the external magnetic field transformed the dominant wear mechanism from abrasive wear to adhesive wear. The influence of the external magnetic field on fretting wear has been demonstrated to manifest in dual aspects: Firstly, the Hertzian contact stress at the interface is enhanced by the magnetic field induction force, resulting in a remarkable reduction of about 79.83 % in accumulated dissipation energy; Secondly, the effectiveness of debris being expelled from the worn interface decreased, and the wear progression was further impeded by the accumulated debris, so that the abrasion loss is significantly reduced by about 60.66 %. These findings provide valuable theoretical data and practical reference for the protection of fretting damage in ferromagnetic materials under the action of a magnetic field.

Effects of hydrogen on the fretting wear behavior of laser cladded FeCoCrNiMo0.2 high entropy alloy coating

This study investigates laser-cladded high entropy alloy (HEA) coatings on high-speed train axles to enhance wear resistance under specific fretting conditions. Axles in humid and acidic environments absorb hydrogen, leading to accumulation in grain boundaries, which weakens their structure and causes damage under alternating stress. Despite this, the impact of hydrogen damage on the fretting wear behavior of HEA coatings has not been explored. To address this, we performed fretting wear tests on a laser-cladded FeCoCrNiMo0.2 coating and a GCr15 steel ball friction system, evaluating their performance before and after hydrogen exposure. The results of the study indicate that under a constant load of Fn = 10N and a displacement amplitude of D = 50 μm, the friction coefficient, maximum wear depth, wear volume, and wear rate increased when the system was in the hydrogen charging state compared to the non-hydrogen charging state. Specifically, the friction coefficient increased from 0.60 to 0.93, the maximum wear depth increased from 2.82 μm to 3.63 μm, the wear volume increased from 14.106 × 104μm3 to 22.098 × 104μm3, and the wear rate increased from 28.213 × 10−6 mm/Nm to 36.600 × 10−6 mm/Nm. Under the hydrogen charging state, the friction coefficient, maximum wear depth, wear volume, and wear rate all increased. This is due to hydrogen damage, including the formation of pitting pits and cracks on the surface of the coating, stress concentration, and brittle failure caused by hydrogen infiltration into the material. The presence of hydrogen makes the surface of the coating more prone to detachment, resulting in finer wear debris, deeper grooves, and increased oxidation. These factors accelerate the wear of the coating. This finding will contribute to the development and improvement of advanced surface modification techniques for materials in the hydrogen environment.

Mechanical and tribological performance of NaOH-Treated bamboo fiber-reinforced recycled HDPE composites under fretting wear conditions

ABSTRACT The study investigates the impact of bamboo fiber reinforcement on the mechanical and tribological properties of recycled high-density polyethylene (rHDPE) composites. Bamboo fibers extracted from locally sourced Bambusa Balcooa were subjected to a comprehensive alkali treatment to enhance their properties, including increased crystallinity, thermal stability, and altered morphology. The treated bamboo fibers were incorporated into rHDPE using a compression molding technique at varying weight percentages (0.5–2.0 wt-%). The results revealed that optimal mechanical performance, particularly tensile strength (155.7 MPa) and modulus (6.6 GPa), was achieved at 1.5 wt-% fiber content, attributed to effective load transfer between the matrix and fibers. Beyond this content, performance declined due to fiber agglomeration and poor dispersion. Flexural properties mirrored these findings, with the highest strength (207.5 MPa) and modulus (11.7 GPa) observed at 1.5 wt-%. Thermogravimetric analysis (TGA) and X-ray diffraction confirmed enhanced thermal stability and crystallinity in treated fibers. Fretting wear tests indicated a reduction in the coefficient of friction with increased fiber content, particularly at lower loads, while wear loss was minimized at 1.5 wt-% BF, suggesting optimal reinforcement. SEM analysis highlighted microstructural changes, including fiber pull-out, debonding, and void formation, correlating with the observed mechanical degradation at higher fiber contents. .

Effect of laser energy on the fretting wear resistance of femtosecond laser shock peened Ti6Al4V

Femtosecond laser shock peening (FsLSP) is performed on engineering alloys to improve their wear resistance in dry and oil-lubricated sliding conditions. In this study, the influence of FsLSP on the fretting wear behavior of Ti6Al4V alloy is studied. For this purpose, FsLSP treatment, with laser energies of 50, 100, 150, and 200 μJ, is performed on a Ti6Al4V sample which mainly consists of α-phase. Topographical investigations using white light interferometry reveal that with increase in the laser energy, the coverage area of laser-induced periodic surface structures (LIPSSs) decreases, and the extent of surface pitting damage increases, leading to higher surface roughness. While surface hardness also initially increases with increasing laser energy, it remains invariant when the energy is increased beyond 150 μJ. Sub-surface microstructural investigations and kernel average misorientation maps obtained from electron backscatter diffraction reveal that FsLSP treatment leads to the formation of severely deformed and mildly deformed layers along the depth of the alloy surface. Surface hardening due to FsLSP is attributed to the activation of prismatic <a>, basal <a> slip systems, and 101¯2, 112¯3 tensile twins in the severely deformed zone along with grain refinement, which is an outcome of dynamic recrystallization. Fretting wear tests indicate that the coefficient of friction (CoF) of FsLSP treated alloys is consistently lesser than that of its as-received counterpart, whose CoF is 0.38. In contrast, the wear resistance, quantified by the wear rate, wear volume and wear depth, is highest in the sample treated with laser energy of 100 μJ but lower for the as-received as well as 150 and 200 μJ laser treated samples. These results are explained on the basis of the differences in the contact area, formation of surface hardening layer and the size and integrity of asperities on the surface, which in turn influences the dominant fretting wear mechanism.

Fretting wear mechanism of DZ125 surface created by WEDM

In this paper, the fretting wear mechanism of the directionally solidified superalloy (DZ125) surface created by wire electrical discharge machining (WEDM) are studied. Samples with varying surface characteristics are prepared by changing the number of wire cutting (NWC), ranging from one to five times (NWC-1 to NWC-5). Comparative analysis reveals that the NWC-3 exhibits the best surface characteristics. Subsequent fretting wear tests under different displacement amplitudes show increased dissipation energy with greater displacement. Compared with other samples, NWC-3 in the synergistic effect of surface roughness and hardness exhibits excellent fretting wear performance. In addition, the fretting mechanism transitions from mixed slip regime (MSR) to gross slip regime (GSR) as the displacement increases. The wear mechanism transitions from abrasive wear to oxidation wear and adhesive wear.

Impact and tangential composite fretting wear of Zr-4 alloy tubes under random loading conditions

The fuel rod casing tube is a crucial component in pressurized water reactor (PWR) nuclear power plants. Flow-induced vibrations in the circulating water can result in complex alternating fretting wear between the casing tube and the positioning lattice frame. Existing research on fretting wear has primarily focused on unidirectional wear, with limited investigation into composite fretting wear under complex working conditions. This study conducted impact and tangential composite fretting wear tests on Zr-4 alloy tubes under varying constant and random impact loads to examine fretting wear behavior. The findings show that the peak friction coefficients in the impact and tangential composite fretting wear tests were consistent across the three constant load conditions, with higher peak friction coefficients observed under random load conditions and a longer time required to reach these peaks during micromotion tests. Comparative analysis revealed that random impact and tangential composite fretting wear caused the most severe damage. Under constant load conditions, wear damage became more severe with increasing load, transitioning from oxidized and adhesive wear to a peeling layer as the load intensified in the impact and tangential composite fretting wear tests.

Role of various influencing parameters on high temperature fretting behaviour of different tribopairs in liquid lead

The increasing interest in liquid metal cooled nuclear reactors provides technical and scientific challenges such as the understanding, prevention, and prediction of the degradation of materials in liquid lead. Critical components include the fuel rods, heat exchanger tubes, and pump impellers. These functional elements are exposed to mechanical loading (up to 40 MPa), high temperatures (450–550 °C), and fluid-induced vibrations (up to 25 Hz). Under such conditions, fretting wear occurs between e.g., the spacer wire and the outer surface of the fuel or heat exchanger tubes. This work is aimed to establish a laboratory-scale fretting wear test setup and develop test methodology to enable systematic material characterisation in liquid metal environments. The results obtained by using the described methodology indicate that adhesive wear is the dominant degradation mechanism, and 316L stainless steel shows a higher coefficient of friction but a lower wear volume/tribolayer volume compared to 100Cr6 bearing steel. These results are in agreement with those reported in open literature and demonstrates the suitability of the presented method for conducting fretting tests and analysis for various materials and contact configurations in liquid lead environment.

Variable cycle fretting conditions meditated wear behavior and mechanism in a self-lubricating composite coating on TC21 titanium alloy substrate

To simulate the variational working conditions of the titanium fastener in the aero-engine, variable cycle fretting wear tests were carried out for normal loading (80/40 N), frequency (100/30 Hz), displacement amplitude (80/40 µm) and operating temperature (500/350 °C) in a self-lubricating composite coating on TC21 titanium alloy substrate, and the fretting wear behavior and wear mechanism were thoroughly investigated. The results shows that the coefficient of friction (COF) and the wear volume present a significant difference under variable cycle fretting conditions. The specimen exhibits a relatively stable COF under variable operating temperature. Whereas for the specimen under variable displacement amplitude presents a lowest wear volume. The adhesive wear is mainly found in the specimens under variable normal loading and frequency. Whereas for the specimens under variable displacement amplitude and operating temperature, abrasive wear and oxidation wear is mainly dominated, respectively. The dissipated energy calculation results demonstrate that the variable displacement amplitude and operating temperature have greater impact on the fretting wear behavior. The microstructure analysis in the cross-section of specimens reveals that the sub-surface is composed of amorphous-nano crystalline layer, plastic deformation layer and the origin coating. Additionally, the wear mechanism of the specimens under variable fretting conditions were deeply revealed. This work can provide essential information on fretting behavior and mechanism under the variational working conditions.

The oil lubricated fretting wear behavior under different sliding displacements and frequencies of Ti6Al4V titanium alloy as affected by micro-shot peening

The fretting wear behavior under oil lubricants is of great practical significance since oil is usually used to regulate fretting regime for minimizing wear. In this study, micro-shot peening (MSP) was performed on Ti6Al4V titanium alloy, in which 0.6 MPa injection air pressure, 60 s shot time and high-speed steel particles with an average diameter of 50 μm were used. Surface topography, microstructure, hardness and compression residual stress of test samples were examined. Oil lubricated fretting wear tests were then conducted between titanium alloy sample and GCr15 counterbody under different sliding displacements and frequencies. The test results show that the surface structure of MSP treated samples experienced severe plastic deformation, the surface hardness was increased from 310.8 HV to 433.5 HV, and a compression residual stress of −303.5 MPa was introduced within surface layer. Moreover, MSP treatment reduced the coefficients of friction through producing a micro-dimpled surface. Thereby, the fretting wear resistance of MSP treated sample under oil lubricated condition was improved. By comparison, at higher sliding displacement and frequency, the ability of MSP treatment to resist fretting wear was improved more significantly since more better lubricating effect can be obtained. Fretting damage of untreated sample under oil lubrication was mainly attributed to fatigue wear, delamination wear, abrasive wear and oxidation wear, while that of MSP treated sample was mainly regional peeling off and abrasive wear.

Three-dimensional representative modelling for fretting wear and fatigue of submarine power cable conductors

Submarine power cables (SPCs) for floating offshore wind turbines (FOWT) have received relatively little attention compared to the structural design of wind turbines. This is particularly true for the assessment of fretting-related damage in multi-strand copper wire conductors, due to the complexity of the contact interactions and potentially severe dynamic loading. In this paper, a three-dimensional representative crossed cylinder methodology is introduced to identify potential inter-wire fretting damage. The approach is based on a global–local methodology for FOWTs. Fretting wear testing of crossed cylinder copper specimens are used to characterise the friction and wear behaviour and validate the local fretting wear simulation. A multiaxial wear-fatigue methodology is implemented in conjunction with the global–local methodology for prediction of effects of normal operating and extreme floating wind SPC design load cases. It is shown that gross slip wear has a beneficial effect on predicted fatigue life by about two to three orders of magnitude. The work demonstrates a global–local modelling methodology for design of SPC conductors in floating wind applications.

Effect of rolling-texture intensity on fretting damage and subsurface deformation behavior in a high-strength titanium alloy

Fretting damage is common in the high-strength titanium alloy fastener widely used in the aeronautic industry, leading to the failure of fastening fit or the initiation of crack. The titanium alloy fasteners often have typical preferred orientation characteristics (i.e., texture), and this is one of the important factors affecting its performance. However, the investigations on the mechanism of β rolling-texture intensity on fretting damage resistance and subsurface deformation are less addressed. Hence, fretting wear tests were carried out on samples with different rolling texture intensities. The results demonstrate that the samples with quite low (A-10 % sample) and quite high (D-70 % sample) rolling-texture intensity both exhibit excellent fretting wear resistance, but their mechanisms are completely different. Uniformly dispersed grain orientation renders the A-10 % sample with good recovery ability and a positive friction effect during wear. Low stress only concentrating at grain boundaries (GBs) weakens cracks’ initiation and propagation. The unique orientation-layered structure (OLS) leads to excellent recovery ability and a positive friction effect. Crack propagation is inhibited and only propagates along the OLS boundary without a connected trend. However, samples with moderate rolling texture intensity exhibit severe wear. Dislocations are restricted in local areas, so the poor recovery ability makes them have a negative friction effect. Crack propagation driving force continuously increases. Appropriate rolling texture intensity can reduce wear by three times. This study can provide information on the principle for designing fretting damage-resistant alloys.

Synergistic mechanism of the fretting wear resistance of Fe2O3/Ag nanostructured coatings prepared by sliding friction and magnetron sputtering

The synergistic effect of the hard/soft phases of a material is potentially valuable and significant for improving wear resistance. Given this, a method for preparing Fe2O3/Ag nanostructured coatings, in which reciprocating sliding friction is used to prepare nano-Fe2O3 coatings and magnetron sputtering is used to prepare nano-Ag coatings, is proposed. The fretting wear test using a SiC ball as the friction pair shows that a large amount of oxide accumulates on the friction pair surface of the substrate, while that of the coating is smooth, and the coating greatly improves the wear resistance of the sample. In particular, the Fe2O3/Ag coating has better fretting wear resistance, and the wear rate is as low as 7.03 × 10−6 μm3N−1μm−1. The excellent tribological properties of Fe2O3/Ag nanostructured coatings at room temperature are derived from the Ag–Fe2O3 nanocomposite layer with a Ag composition gradient, which is formed by Ag nanoparticles gradually penetrating into the Fe2O3 layer under the normal load produced during fretting wear. Furthermore, the Ag/Fe2O3 semi-coherent interface, which is induced between Ag and Fe2O3 nanoparticles under fretting wear, endows the composite layer with excellent thermal and mechanical stability. This design idea of using a fretting wear load to prepare composite coatings with the synergistic effect of hard and soft phases to strengthen the wear performance of a workpiece also provides a reference for the preparation of other hard/soft heterogeneous coatings.

Fretting wear characteristics evolution mechanism of 60Si2MnA steel for high-speed railway fastener clips

The fastener clips of the high-speed railway may fracture due to accumulated fretting damage, posing a hazard to train operation safety. To investigate the evolution mechanism of fretting wear characteristics of high-speed railway fastener clips, this paper conducted fretting wear tests on 60Si2MnA steel used for clips and analyzed the fretting wear characteristics under different number of fretting cycles ( N). The results indicate that as N increases, the friction coefficient rises initially, then falls, slightly rises again, and eventually stabilizes. Furthermore, the surface wear volume and depth of 60Si2MnA steel material increase continuously, and its fretting wear mechanism undergoes a transformation. Specifically, at 20,000 cycles, surface plastic deformation primarily causes material damage. While at 40,000 cycles, an oxide plastic deformation layer appears on the material surface, where adhesive wear and oxidation wear become the primary wear mechanisms. When N increases to 80,000, plastic strain accumulates continually on the material surface, causing the oxide plastic deformation layer in the outer contact area to break and detach gradually. Adhesive wear transforms into abrasive wear, cracks occur inside the material, and fatigue wear becomes a significant wear mechanism. This study fills the research gap in the fretting wear evolution mechanism of 60Si2MnA steel.

Study on bi-directional composite fretting wear characteristics of Zr-4 alloy tube with different phase differences under temperature conditions

The Zr-4 alloy tubes in nuclear fuel rods in pressurized water reactor (PWR) fuel assemblies were subjected to bi-directional composite fretting wear tests with different phase differences (0°, 90°, 180°, and 270°) at room temperatures and 300 °C by using a multi-modal fretting wear tester developed independently by the group. The experimental results show that the change in temperature as well as the change in phase difference has a significant effect on the fretting wear characteristics of Zr-4 alloy cladding tubes.The following conclusions were drawn: Among the bi-directional composite fretting tests with different phase differences, the most severe wear was observed for the bi-directional composite fretting test with a phase difference of φ = 90°. Bidirectional composite fretting wear tests at 300 °C show more intense wear and more severe damage compared to room temperature tests. At room temperature, the morphology of the abrasion mark region is characterized by zoning, and the wear mechanism is mainly dominated by adhesion wear, abrasive wear and delamination.

An Investigation into the Relative Efficacy of High-Velocity Air-Fuel-Sprayed Hydroxyapatite Implants Based on the Crystallinity Index, Residual Stress, Wear, and In-Flight Powder Particle Behavior.

Due to its resemblance to the bone, hydroxyapatite (HA) has been widely used for bioactive surface modification of orthopedic implants. However, it undergoes significant thermal decomposition and phase transformations at a high operating temperature, leading to premature implant failure. This investigation uses high-velocity air-fuel (HVAF) spray, an emerging low-temperature thermal spray technique, to deposit HA over the Ti-6Al-4V substrate. Coating characteristics, such as the crystallinity index and phase analysis, were measured using X-ray diffraction, Raman analysis, and Fourier transform infrared spectroscopy, residual stress using the sin2ψ method, and tribological performance by a fretting wear test. The coating retained an over 90% crystallinity index, a crystallite size of 41.04 nm, a compressive residual stress of -229 ± 34.5 MPa, and a wear rate of 1.532 × 10-3 mm3 N-1 m-1. Computational in-flight particle traits of HA particles (5 to 60 μm) were analyzed using computational fluid dynamics; it showed that 90% of particles were deposited at a 700 to 1000 m/s velocity and a 900 to 1450 K temperature with a 2.1 ms mean residence time. In-flight particle oxidation was minimized, and particle impact deformation was maximized, which caused severe plastic deformation, forming crystalline, compressive residual stressed coatings. The thermal decomposition model of low-temperature HVAF-sprayed HA particles helped to understand the implants' crystallinity index, residual stress, and tribological characteristics. Hence, this experimental and computational analysis shows that the HVAF process can be a promising candidate for biomedical applications for having strong and durable implants.

A novel test apparatus to study the mechanism of harmonic normal force on fretting wear

Fretting wear significantly affects the hysteresis behavior of the contact surface and leads to joint degradation due to material removal. Although numerous tests have been conducted to investigate fretting wear under constant normal force, the applied mechanical load on the contract surface more or less deviates from that in the operational condition. The normal force is typically time-varying due to the coupling of tangential and normal vibration, rather than remaining constant. The time-varying normal force can be regarded as the superposition of harmonics for steady-state vibration which is widely encountered in engineering. In this paper, we investigate how would the harmonic component of the normal force affect the evolution of interface morphology and contact parameters with fretting wear. To do that, we design a novel fretting wear test apparatus that generates the stable harmonic normal force. The normal force is controlled by a closed-loop control system, ensuring its consistency throughout the entire wear test. In addition, we develop various subsystems to realize different functions like support, constraint and measurement, enabling the acquisition of hysteresis loops under different normal forces. The critical performances of the test apparatus (e.g. force transfer, closed-loop control and repeatability) are also demonstrated. Results indicate that the harmonic normal force can significantly influence the hysteresis loop and the energy dissipation distribution on the contact surface. In comparison to the constant normal force, the worn surface has a higher degree of non-uniformity, characterized by alternating pits and prominences. Furthermore, the friction coefficient exhibits an outstanding upward trend after reaching a steady state, while the tangential contact stiffness continuously weakens as fretting wear progresses. These unique evolution characteristics could be attributed to the non-uniform energy dissipation caused by the harmonic normal force acting across the fretting space. This viewpoint can be partly validated through observing the interesting hysteresis loops, which are captured by the test apparatus.

Fretting wear behavior of oxide dispersion strengthened nanocrystalline-amorphous FeCr film

Fretting wear is potential safety hazard for critical structural components in various industries, including nuclear reactors and aerospace. Surface treatment can effectively reduce damage caused by contact. The focus of this work is to prepare Y2O3 oxide dispersion strengthened FeCr-based films by magnetron sputtering. The distribution of Y2O3 and its effects on the mechanical properties, as well as the fretting wear behavior of the films were characterized in detailed. The results show that Y2O3 nanoparticles are uniformly dispersed in the FeCr films matrix, forming a nanocrystalline-amorphous composite structure. As the Y2O3 content increases, the FeCr films show a trend of grain refinement and hardness increase. The fretting wear tests of FeCr-based films sliding against Al2O3 and GCr15 counterparts were conducted, and the best friction-reducing performance was achieved when the co-deposition power of Y2O3 is 70 W. To elucidate the underlying friction mechanism, transmission electron microscopy (TEM) characterization was utilized to reveal the microstructure evolution of the films and the contribution of friction products. This study provides valuable insights into the development of wear-resistant materials made from nanocrystalline-amorphous dual-phase structure films dispersed by rare earth oxides.