Experimental design is an effective method for conducting a reduced number of experiments in order to obtain the optimum spraying conditions and enhance the thermally sprayed coatings properties. In the present study, a 3(3) factorial design experiment was used to establish the effects of the variables on the coatings quality in relation to the corrosion behavior of an HVOF Ni based self-fluxing alloys coatings in a 3.5% NaCl solution. Response surface methodology was employed to describe empirical relationships among variables as the spraying distance, the fuel/oxygen ratio and the powder feed rate. The maps obtained allowed the selection of the optimum operating conditions to achieve the desired specifications of the HVOF coatings for their best corrosion resistance in the chosen environment. The analysis of the results indicates that the spraying distance, the fuel/oxygen ratio and the powder feed rate have a significant effect on the porosity and corrosion resistance of these coatings.