The aim of the paper is to investigate the rolling contact fatigue mechanism of the Fe–Cr alloy coating under different stress conditions. The Fe–Cr alloy surface coatings and Ni–Al alloy undercoatings were respectively deposited on the steel substrates using a high efficiency plasma spraying system. The distribution of maximum stress and shear at the interface and the inside of the coating were obtained using finite element simulation and experiment. The maximum stress is the critical failure stress, and shear stress does the main driving force for coating failure. The different failure modes are due to the synergy of the maximum stress and the shear stress.
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