Effect of pulsed femtosecond laser shock peening surface modification on anti-wear failure properties of AISI 9310 gear steel

•FLSP improves physical properties of AISI 9310 steel and friction behavior.•Hardened layer, surface hardness, fine grain jointly improves wear resistance.•Hardened layer is the most important factor affecting the wear properties.•FLSP of 150 μJ & 15 μm achieves optimal wear resistance. The wear resistance of gear components significantly influences operational reliability and lifespan of mechanical equipment. Compared with nanosecond time scale laser surface treatment, femtosecond laser shock peening (FLSP) has the advantage of no absorption layer and constraint layer in processing complex geometric structure parts. However, attempts at FLSP for gear materials are quite limited up to now. This paper introduces a methodology employing Pulsed FLSP to enhance the wear resistance of AISI 9310 gear steel. The research delves into the effects of FLSP on the surface morphology, mechanical characteristics, and wear performance of AISI 9310 steel under varying laser energy levels (50 μJ, 100 μJ, 150 μJ, 200 μJ) and pulse spacings (10 μm, 15 μm, 30 μm). The findings reveal that femtosecond laser surface treatment significantly augmented surface microhardness by 9.4 % to 17.4 % and induced a surge in surface residual compressive stress (RCS) by 30.5 % to 103.1 %. Moreover, it introduced a work hardening layer of 150–300 μm in depth direction, resulting in a wear rate reduction ranging from 10.1 % to 61.7 %. The sample treated with 15 μm pulse spacing and 150 μJ laser energy exhibited simultaneously the lowest wear rate and a minimum average coefficient of friction (COF) on 0.47. The advancement in wear resistance is attributed to the synergistic effects of markedly increased surface hardness, gradient hardness in depth direction, and reduced grain size induced by FLSP. A multiple linear regression (MLR) model indicates that deeper work hardening layers are most significant for improving wear resistance, which reduces risk of wear failure.