In the kinetic spray process, metallic particles are injected into a supersonic gas stream and accelerated to high velocities. When the particles impinge upon a substrate, they are plastically deformed and they bond to the substrate and to one another. In this process, a number of process parameters may affect the particle velocities and particle temperatures, and thus, affect coating formation. In the present study, various spray variables for the large particle sizes are systematically investigated through computational modeling and experiments. The relatively large size aluminum particles (63-90 µm) are used in this study. Effects on coating deposition are discussed in terms of loading behavior, deposition rate and deposition efficiency of the coatings. It was found that the coating formation is critically controlled by particle temperature, in addition to particle velocity.