AbstractStem modularity in total hip replacement introduces an additional taper joint between Ti‐6Al‐4V stem components with the potential for fretting corrosion processes. One possible way to reduce the susceptibility of the Ti‐6Al‐4V/Ti‐6Al‐4V interface to fretting is the surface modification of the Ti‐6Al‐4V alloy. Among the tested, industrially available surface treatments, a combination of two deep anodic spark deposition treatments followed by barrel polishing resulted in a four times lower material release with respect to untreated, machined fretting pad surfaces. The fretting release has been quantified by means of radiotracers introduced in the alloy surface by proton irradiation. In a simple sphere on flat geometry, the semispherical fretting pads were pressed against flat, dog‐bone shaped Ti‐6Al‐4V fatigue samples cyclically loaded at 4 Hz. In this way a cyclic displacement amplitude along the surfaces of 20 μm has been achieved. A further simplification consisted in the use of deionized water as lubricant. A comparison of the radiotracer results with an electrochemical material characterization after selected treatments by potentiostatic tests of modular stems in 0.9% NaCl at 40°C for 10 days confirmed the benefit of deep anodic spark deposition and subsequent barrel polishing for improving the fretting behavior of Ti‐6Al‐4V. © 2007 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater, 2008