This study investigated the effects of spray parameters on wear behavior of the Ni-based hard coatings fabricated by thermal spray process. The experiment was designed by an orthogonal array, the Ni-based hard coatings were fabricated according to this experimental design. The wear test was performed on these coatings using ball-on-disk wear tester. The ANOVA was used to analyze the effects of spray parameters on the wear rate of these coatings, as a result, oxygen gas flow and acetylene gas flow were determined as main factors effected on the wear rate. The effects of these two factors on wear behavior were observed by using SEM and EDX.