Fretting fatigue damage occurs in contacting parts when they are subjected to fluctuating loadings and sliding movements at the same time. This phenomenon may occur in many applications such as bearings/ shafts, bolted and riveted connections, steel cables, and steam and gas turbines. In this paper, the effect of elevated temperature on fretting fatigue life of Al7075-T6 is investigated using a new device for fretting fatigue tests with variable crank shaft mechanism. Also a finite element modeling method was used to estimate crack propagation lifetime in aluminum alloy, Al7075-T6 specimens at elevated temperature under fretting condition. In this method, shear and normal stresses that are caused by contact load are updated at each crack growth increment. Finally, a comparison between the experimental and numerical results is done in order to evaluate the FE simulation. Department of mechanical engineering, Islamic Azad University, Takestan Branch, Takestan, Iran The experimental results show that: (i) fretting fatigue life of the material increases with temperature up to 350°C by 180% for low stresses and decreases by 40% for high stresses, (ii) this fashion of variation of fretting fatigue life versus temperature is believed to be due to degradation of material properties which occurs by overaging and wear resistance increase due to oxidation of aluminum alloy. While overaging gives rise to degradation of mechanical strength of material and hence the reduction of its fretting fatigue life, surface oxidation of the specimens brings some improvement of fatigue behavior of the material. Metallurgical examination of the specimens reveals that temperature results in precipitation of impurities of al-7075-T6. The size of precipitated impurities and their distances gets bigger as temperature increases. This could be a reason for material degradation of specimens which are exposed to heating for longer time duration.
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