This paper analyses the influence of specific coating parameters such as robot velocity, spray distance and part cooling on the risk of crack formation within Chromium- Carbide / Nickel-Chromium coatings. To understand the effect in more detail, metallographic investigations were conducted. These also provide sufficient data to examine other important coating characteristics such as porosity, mechanical stresses and homogeneity. As an additional analytical method Element Mapping is utilised to show the level of oxidation and its impact on the coating microstructure. The methods X-ray diffraction (XRD) and In-situ coating property (ICP)-Sensor are used to investigate the development of stresses in different coatings. With the information from all these examinations a concept was derived to achieve thick, crack-free wear protective coatings.