This study investigates fretting wear in Ti6Al4V (TC4/TC4) contacts under varying loads, displacements, and temperatures, simulating aero-engine components. A ball-on-flatbed setup assessed friction, wear rates, wear mechanisms, oxide/tribo layers, and crack behavior. Results demonstrate that higher loads and displacements reduce friction and wear. Maximum wear occurs at 400°C: abrasive/mild adhesive wear dominates at RT-300°C, transitioning to severe oxidative/delamination wear at 400°C, while stable oxide layers (mild oxidative wear) form at 600°C under lower loads. Higher loads/displacements deepen cracks (particularly at 600°C), accelerating thermally fatigue wear. High temperatures and mechanical stresses promote vertical crack propagation, while subsurface cracks form under lower loads. These findings reveal mechanical-thermal synergies, aiding aerospace wear resistance by optimizing conditions to stabilize oxides and mitigate cracking.’