Fretting behavior of Cu-Al coating on Ti-6Al-4V substrate was investigated with and without fatigue load. Soft and rough Cu-Al coating resulted in abrasive wear and a large amount of debris remained at the contact surface which caused an increase in tangential force during the fretting test under gross slip condition. Fretting in the partial slip condition also showed the wear of coating. To characterize wear, dissipated energies during fretting were calculated from fretting loops and wear volumes were obtained from worn surface profiles. Energy approach of wear analysis showed a linear relationship between wear volume and accumulated dissipated energy. This relationship was independent of fatigue loading condition and extended from partial slip to gross slip regimes.

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