To use the manifold possibilities that arc spraying offers to deposit wear resistance layers, the knowledge of the particle formation and their behaviour are necessary. This work is focused on studying the particle properties during arc spraying with cored wires. Different cored wires under various spraying parameters are investigated by means of a high speed camera. Particle properties in-flight, such as velocity and temperature are determined. Correlation between particle behaviour and particle characteristics at different spraying conditions are established. 
At the same time, the particle-laden gas flow is simulated numerically and the computed solutions are used to illustrate the utility of the proposed CFD-model and compared with experimental results. The employed mathematical model represents a system of macroscopic conservation laws for the continuous gas phase and for the gas-solid mixture. This approach formulation makes it possible to circumvent the numerical difficulties associated with the implementation of a (potentially ill-posed) two-fluid model. The discretization in space is performed using a high-resolution finite element scheme based on algebraic flux correction in terms of local characteristic variables. The artificial diffusion operator is constructed on the discrete level and fitted to the local solution behaviour using a multidimensional flux limiter of TVD type.