Characterization and solid particle erosion behavior of plasma sprayed alumina and calcia-stabilized zirconia coatings on Al-6061 substrate

► Thermal stresses developed during spraying were main causes for presence of micro-cracks in the coatings. ► For the highest adhesion values, coating failure was mainly located in the bond coat/substrate interface. ► Erosion wear was more at 45° angle of impact showing that erosion behavior as a composite ductile-brittle. ► Erosion of coating systems occurred through spalling of lamella exposed on coating surface resulting from cracking along the lamellar interface.