The present work aims at study the influence of the most important processing parameters on the microstructure and some mechanical properties of plasma sprayed coatings with Ni-based powder. The powder used for spraying was mechanical mixture of Ni-Cr-B-Si-C-Fe. Experiments are performed at different processing conditions including current strength, gas flow rate and ratios between the primary (Ar) and secondary (N2) gases. Microscopy study and X-ray diffraction analyses are used to characterize the microstructure and phase compositions of coatings obtained at different processing parameters. The influence of the spraying parameters on the hardness, adhesive strength, porosity, roughness and wear-resistance of the coatings is investigated. The results obtained are used to optimise the processing parameters for existing applications in the plasma spraying industry. Examples are given for use of the results obtained to design plasma spraying technologies for new applications.