Wire arc is an effective and affordable type of coating process. Detailed understanding of it helps improving design and optimization of currently available guns. In wire arc process, an arc forming between two charged wires generates enough heat to melt the metallic wires. Blow of air at high velocity over this bath of molten metal leads to atomization. The formed droplets are then accelerated towards the substrate where they impact and solidify during the coating process. The current work is a follow up to our earlier numerical study where numerical simulation of wire arc spraying using ANSYS FLUENT revealed flow circulations inside the gun can affect flow pattern and contribute to energy dissipation. In this study, an attempt has been made to validate and measure this matter using experimental procedures and to seek potential ways of improvement.