The main purpose of this paper was to investigate the effects of the different frequencies and loads of multi-pass ultrasonic surface rolling (MUSR) on surface layer mechanical properties, microstructure and fretting friction and wear characteristics of HIP (hot isostatic pressing) Ti-6Al-4V alloy. Some microscopic analysis methods (SEM, TEM and EDS) were used to characterize the modified surface layer of material after MUSR treatment. The results indicated that the material in sample surface layer experienced a certain extent plastic deformation, and accompanied by some dense dislocations and twins generation. Moreover surface microhardness and residual stress of samples treated by MUSR were also greatly improved compared with the untreated. The fretting friction and wear properties of samples treated by MUSR in different conditions are tested at 10 and 15 N in dry friction conditions. It could be found that friction coefficient and wear volume loss were significantly declined in the optimal result. The main wear mechanism of MUSR-treated samples included abrasive wear, adhesion and spalling. (C) 2016 Elsevier B.V. All rights reserved.