Abstract The effects of powder types and HVOF spray systems used to produce Cr 3 C 2 -NiCr coating on the relationships between spray parameters and wear performance were investigated based on the effect of fuel gas conditions on abrasive wear and erosion wear. The relationships between spray parameters and wear properties were obtained by orthogonal regression experimental design method. Four types of powders and two HVOF spray systems were used. It is found that with the increase in fuel gas flow or pressure the abrasive wear and erosion of Cr 3 C 2 -NiCr coatings change following a concave curve. The Cr 3 C 2 -NiCr coating with the best wear performance will be deposited under intermediate fuel gas condition. It is experimentally confirmed that by different types of powders and HVOF systems applicable to HVOF spraying of Cr 3 C 2 -NiCr coating, although the optimized fuel gas conditions to deposit coating with the best wear performance will be influenced by types of starting powders.