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Based on the 'fluff' a normal marine legion has armourers that repair everything between battles, but if your particular group happen to be on a deeply embedded campaign without support staff, then you could totally justify some (or even lots) of battle damage built up over time.

I like the idea that the higher rank people would have the best repairs too - assault marines/scouts could have a lot of 'blade damage' type marks, devastators with burns/dirt, tacticals with the occasional bullet damage, scuffed up knees etc.

I think to be honest you'd be hard pressed to make it look too much.

One thing I look for is to have the weathering in specific areas - the leading edge of power fists, knee plates, shields, etc. More 'random' chaipping doesn't always look as good to my mind - sometimes it looks more corrosion-like than battle damage. Think about shich surfaces get the most abuse and work on those.