Surface Fatigue Behavior of Duplex Ceramic Composites Under High-Frequency Impact Loading with In Situ Accelerometric Monitoring

In applications involving repeated high-frequency mechanical impacts, such as cutting, machining, or percussive operations, understanding the surface fatigue performance of advanced ceramics is critical. This study investigated the surface fatigue resistance of duplex oxide–carbide ceramic composites fabricated via spark plasma sintering, complementing prior work on their sliding wear performance. The composites, featuring a hybrid oxide–carbide structure, were tested using a cyclic impact setup with a 10 mm ZrO2 ball activated with 12 hammers fixed to a rotary disc delivering 500,000 impacts per test. Surface degradation was quantified through three-dimensional profilometry to determine the net material loss and scar depth, while fatigue mechanisms were analyzed using scanning electron microscopy coupled with energy-dispersive spectroscopy. In situ monitoring was implemented using accelerometers to capture vibrational signatures during cycling loading, enabling real-time assessment of material response and damage evolution. The WC-containing composite (S2 AZW) exhibited the lowest surface fatigue wear loss (700 × 103 µm3), whereas the ZrC-based composite (AZZ1) showed the highest (1535 × 103 µm3). A distinct inverse correlation was observed between the average peak acceleration and fatigue wear loss. Frequency-domain analysis of accelerometric signals revealed progressive degradation patterns consistent with post-test surface damage, indicating that such signal features may serve as effective in situ indicators for tracking material fatigue in future applications.