Competing failure mechanism and life prediction of plasma sprayed composite ceramic coating in rolling–sliding contact condition

The competing failure mechanism and life prediction of plasma sprayed Al2O3-40 wt%. TiO2 composite ceramic coatings under rolling-sliding contact conditions were investigated on a double-roll test machine. The maximum shear stress distribution in the coatings was analyzed by the finite element method. Weibull function was used to characterize the life distribution of the coatings under different rolling–sliding contact conditions. The failure modes were mainly surface abrasion and adhesive delamination during this investigation. The mechanism of the competing between surface abrasion and adhesive delamination was discussed in detail.