Air plasma sprayed tungsten carbide-cobalt coatings are being used at Kelly Air Force Base for a fretting application for convergent seals in aircraft engines. Experimental and analytical studies were conducted to investigate the plasma spraying of two powders for this application. Statistical processing schemes were accomplished in conjunction with analytical modeling of the air plasma spray (APS) process. Classical and statistically designed experiments (SDE) chosen to be conducted were determined by analytical modeling. The coatings were characterized for composition, hardness, porosity, surface roughness, deposition efficiency, and microstructure. Attributes of the coatings are correlated with the changes in operating parameters. Wear screening of the coatings from the experiments was conducted using an abrasion tester based on ASTM Standard Test B611-85.