This study investigates the effects of the ultrasonic surface rolling process (USRP) on the surface integrity and fatigue performance of 18CrNiMo7-6 alloy steel with a high stress concentration factor (Kt = 3). Systematic evaluations under static loads of 400 N and 800 N showed that USRP significantly enhances surface properties: it reduces roughness (Ra) to 0.25 μm and stress concentration coefficient (Kst) to 1.09, while eliminating grinding-induced surface defects. At 800 N, a gradient nanostructure (GNS) forms on the surface, with grain size refined to 0.34 μm at 20 μm depth; dislocation density and low-angle grain boundary proportion increase by 83.77 % and 175.46 %, respectively. An approximately 800 μm-thick gradient hardened layer is generated, exhibiting a maximum microhardness of 847 HV and residual compressive stress of −1440 MPa. Fatigue testing revealed the fatigue limit increases from 627.66 MPa to 1175 MPa (an 85.49 % enhancement), accompanied by a shift in crack initiation sites from surface grinding marks to subsurface oxide inclusions at 0.481 mm depth. This remarkable fatigue improvement is attributed to a multi-scale synergistic mechanism: (1) USRP-induced GNS enhances yield strength via the Hall-Petch effect and increases dislocation density, raising the crack initiation threshold, while improved surface quality further reduces crack nucleation probability; (2) introduced residual compressive stress effectively lowers the driving force for crack propagation, significantly retarding crack growth.
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