The frizzen does not develop gouges or chatter marks, IF THE FLINT'S Angle of Impact is correct.
The reason we use or desire the angle of impact to be 60 degrees is to take advantage of the flint's natural fracture lines, when the edge strikes the steel. At 60 degrees, the Angle of Impact only allows the edge to scrape steel, NOT GOUGE it.
You do need, of course, a properly hardened frizzen. If your sparks are not "white hot" like those off a 4th of July sparkler, the frizzen is probably not hardened sufficiently. It may produce sparks, but they will be red, or orange in color.
You also need a mainspring that has tuned to have no more tension at full cock than about 15 lbs. You are recognizing a problem that does arise on impact of the flint. However, the problem appears in the form of short flint life, or shattered flints, not in gouges, is the angle of impact is correct.
If the AOI is correct, the spring is correct, and the flint set correctly into the jaws, you will get scrape marks. You will also see the edge of the flint Knapped off by the flow of the hammer to the frizzen, each time its fired. A small spawl is taken off the UNDERSIDE of the edge with each strike.
The flint edge does shorten, doing this, and you do need to reposition your flint every 20-25 shots. And since the edge is created by that BEVEL on the front of the flint, knapping off the edge does create a duller flint as it wears back. That is why I recommend re-knapping the flint after its re-positioned.
Re-knapping is done for 2 reasons:
a. To put a new, sharp edge on the flint; and
b. to square the edge to the frizzen. No one can consistently hold a flint square to the frizzen as they turn the cock screw down to tighten the jaws. There is always a bit of movement sideways to the flint as you tighten the cockscrew that last couple of degrees. By knapping the flint as I have previously described-- cradling the gun in your left arm, opening the frizzen using the side of your left thumb, between the nail and air, finding the angle for the frizzen where the flint edge will strike the bottom of the heel of the frizzen by lowering the cock using your right hand, then holding the frizzen at that spot, cocking the gun, and releasing the cock by pulling the trigger----- you get a new sharp edge that is square to the frizzen, across the width of the frizzen.
Unlike using hammers, or rods, or some other method of knapping your edge, the amount of flint that is consumed knapping the edge in this matter is minimal, and produces a nice even, square edge across the width of the frizzen.
Only when the flint is getting well used, do I have to be concerned about more frequent knapping than every 20-25 shots, when I re-position the flint forward. In that situation, I may knapp the flint one more time to finish a match stage, but then, Like Bill, I will remove the flint and replace it. At home, I may see if I can't remove some flint with a dremel tool, or diamond hone, so that I can take it back to the range for practice and get 10-20 shots more out of it. The flint is thrown away when its too short to be held adequately in the jaws of the cock, AND, still reach forward enough in the half cock position to be able to pop that frizzen open on impact.
Creating sparks, that are not thrown down into the pan instantly defeats the purpose of shooting a flintlock action. This is why its important to tune the frizzen and frizzen spring so that it opens properly on impact. In a well tuned flintlock, the tension on that frizzen to open it should not exceed 3 lbs. 1-1 1/2 lbs. is much better.