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Surface deformation in the running-in phase is crucial because it may affect the lifetime of the mechanical system. However, deformation at this phase is very small because it occurs within the asperities and is almost undetectable using conventional mass loss or the wear depth measurement technique. This study aimed to experimentally evaluate the evolution of surface asperities in the running-in phase and gain an understanding of the factors that affect deformation. An experimental rig for the measurement of asperity deformation at a small scale was designed and fabricated for this purpose. The developed rig can quantify the progression of microgeometry asperity deformations without dismounting the sample from the rig to maintain the relative contact and avoid inaccuracy. The precision of this measurement allows online monitoring of real asperity geometry evolution and detection of small changes up to the micrometer scale. The results indicate that the asperity deformation is influenced by the initial asperity geometry. The asperity with a higher asperity slope  Δa  and asperity height  H  as well as a smaller radius  R  is more prone to deformation. The initial  H ,  R m, and  Δa  have a high correlation with asperity deformation  Δh  with high Pearson’s correlation values of 0.92, 0.91, and 0.87, respectively.

Experimental Study of Surface Asperity Deformation in the Running-In of Rolling Contacts