Structural and Morphological Analysis of Shot Peening Effects on Tribological Wear of DMLS‐Manufactured Ti6Al4V Titanium Alloy

The tribological performance of additively manufactured Ti6Al4V alloy is strongly influenced by its metastable microstructure and surface condition. This work investigates the effect of shot peening with ceramic beads and CrNi steel shots on the friction and wear behavior of DMLS‐fabricated Ti6Al4V under technically dry sliding conditions using a ball‐on‐disc configuration with an Al ₂ O ₃ counterbody. Shot peening led to a significant increase in surface hardness (up to ∼42%) and a reduction in surface roughness, resulting in lower friction coefficient and wear rate compared to the as‐built condition. Despite similar hardness and roughness levels, distinct tribological responses were observed depending on the peening media. SEM and EDS analyses revealed phase‐dependent wear mechanisms, indicating that shot‐induced redistribution of the metastable α′ and β phases plays a key role in governing wear behavior.