Erosion due to solid particles impact has a detrimental effect on the performance of components used in various applications. Hard facing is widely used to combat wear in such situations. D-gun coating is increasingly popular for such applications. Alumina-titania composite has been deposited on mild steel substrate. The coating has been characterized and their tribological responses have been evaluated. Resistance to erosion, evaluated through standard dry erosion test is highlighted in this work. An orthogonal full-factorial experimental matrix which includes all possible variables that contribute to brittle erosion was designed, conducted and validated. The variation of erosion rate with process parameters was mathematically modelled by using the regression analysis method. © (2011) Trans Tech Publications, Switzerland.