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This research aims to assess the effect of the debris particle size on the tribological performance and lubrication regime parameters of a Ni-based alloy coating. This is a key industrial problem, and its resolution can contribute to better machine endurance and proper maintenance. The debris particles are simulated by hard Al 2 O 3 particles of size ranging from nanometers to 45 μm and dispersed in an oil lubricant. The coating studied is NiCrBSi deposited by flame spraying technique followed by the Surface Flame Melting (SFM) process. The counterpart disk sample was fabricated from quenched and tempered F-5220 steel (in line with A681(O1) ASTM). This pair was tested under linear sliding contact. Our results show that the addition of alumina particles contributes to a significant increase in wear, particularly for the largest particles (micrometric size). In the case of micrometric particles, it is possible to observe the formation of higher surface roughness, numerous microgrooves, and plastic flow of NiCrBSi coating perpendicular to the sliding direction, resulting in higher loss of volume. It was found that the actual surface roughness (obtained as a function of the debris particle size) allows better identification and prediction of the lubrication regime for wear processes instead of the traditional approach that uses the initial surface roughness as a parameter.

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