Abstract Thermally sprayed aluminium oxide coatings are extensively used for functional applications where high wear resistance is of high significance. Among the various thermal spray coating methods, D-gun (Detonation gun) coating technology produces alumina coatings of excellent quality. Components made with D-Gun coatings are used in industrial as well as automotive applications. There is an increasing need to identify, analyse and determine the improved performance of such coatings. The present work aims to study the characteristics of the bio-lubricant- Esterified coconut oil and its influence on the wear characteristics of such alumina coatings. The effect of the anti-wear additive, Zinc Dialkyl Dithio Phosphate (ZDDP) on the tribological behaviour of the lubricant and hence on the coated samples, has also been studied. The coefficient of friction and wear were found to be decreasing with the addition of ZDDP. The average coefficient of friction was found to be in the boundary lubrication regime