Abstract: A comparative study of porosity, oxide contents, bond strength and wear resistance of 3Cr13 stainless steel coatings deposited by high velocity and regular arc spray processes was carried out. An orthogonal and rotational regression experimental method and an ordinary single factor experimental method were adopted to evaluate the coating hardness with respect to the effect of processing parameters. The quantitative formula of processing parameters with coating hardness was obtained by means of microcomputer. The results show that, compared with the regular arc spray process, a dense coating with lower porosity, higher bond strength and higher oxide contents were produced by a newly developed high velocity arc wire spray process. The bond strength is higher than 40MPa, which is increased by 52 percent than that of regular arc sprayed coatings. The orthogonal and rotational regression experimental results show that the spray distance and the interaction of spray distance and arc current had significant effects on the coating hardness. The results also indicate a great difference between the orthogonal and rotational regression experiment and the single factor experiment.