Nowadays wire arc spraying of chromium steel has gained an important market share for corrosion and wear protection applications. In order to optimize the process parameters and to evaluate the effect of the spray parameters DoE based experiments have been carried out as well. In this paper, the effects of the process parameters of spray current, voltage and atomizing gas pressure on the particle jet properties of mean particle velocity and mean particle temperature as well as plume width are presented. To monitor these values the AccuraSpray system was used. The properties of the coatings with regard to morphology, composition and phase formation are included as well. These investigations are part of the development of new power supplies and the enhancement of spray parameter range. As a result of these experiments the spray parameters can be adjusted according to the requirements of the chromium steel coatings.