Microstructures and properties of the arc-sprayed coatings depend very much on spray conditions. Characterization of the arc sprayed stainless steel in-flight particle, splat and coating produced by weld wire and arc wire were carried out in this work, in order to compare those characteristics obtained from different wire types. Weld wire was sprayed by four different spray conditions while arc wire was sprayed by a recommended condition. Effect of spray parameters on characteristics of the in-flight particle, splat and coating will be presented. Characterization include size analysis, morphology, degree of splashing, degree of flattening, coating microstructure and properties, and also wear performance, are compared and discussed in detail.