采用超音速等离子喷涂设备在45号钢基体上制备了三种含有不同微缺陷的NiCrBSi合金涂层.使用球盘式接触疲劳实验机对涂层的接触疲劳性能进行了测试,建立了Weibull失效概率图；使用扫描电子显微镜对涂层的微观结构和失效形貌进行了表征；比较了三种涂层的接触疲劳寿命及涂层的主要疲劳失效模式.结果表明,涂层内的微缺陷主要由微孔隙和微裂纹构成,涂层接触疲劳寿命的长短与这些微缺陷含量的多少成反比,涂层的孔隙率为2.5％,1.3％和2.1％,对应的接触疲劳寿命分别为7.77×105,8.99×105,7.81×105周次.同时,涂层微缺陷含量较少时涂层的失效模式主要以剥落失效为主；涂层微缺陷含量较多、结合强度较差时主要以分层失效为主；涂层内存在较大的孔隙可致使涂层的提早失效,同时涂层表面磨损失效的概率增加.
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