The hybrid spray process that combines arc-spray with HVOF or plasma jet (APS), has recently demonstrated its effectiveness in the deposition of functionally gradient coatings. This approach aims at exploiting the attributes of both the arc-spray technique combined with those of the HVOF/APS technique, namely, the benefits of using wire stock, high deposition rates and higher coating densities. This paper presents high speed visualization and plume characterization of a generic hybrid spray gun that can either use a HVOF jet or plasma jet along with multiple arcing. The objectives of the study are to explore the physics involved and to qualitatively/quantitatively address the ability of this system to atomize and deposit liquid metal effectively. The physics of atomization in hybrid spray process is examined using high-speed camera (~100,000 frames/sec). High-speed images showed that the liquid breakup at the arc tip is unsteady. Visualization of downstream shows that large molten ligaments continue to undergo secondary breakup far from the arc tip. A DPV-2000 particle diagnostics sensor is used to measure particle velocity, temperature, size and distribution. The influence of feed material, electric arc-spray parameters, and the jet parameters on the particle characteristics is presented. It is observed that the velocity of the particles in the hybrid mode are slightly lower than the velocity of particles by jet alone but significantly higher than typical electric arc-spray velocities. The particles produced by the hybrid gun tend to be more uniform and smaller compared to traditional electric arc-spray. These observations have led to improved nozzle designs that enhance the deposition performance.