In this work, the effect of High Velocity Air Fuel (HVAF) spray parameters on the microstructure and wear behavior of two compositionally different, Fe-based coatings was investigated. Microstructural examination of the as-sprayed coatings was performed using SEM/EDS and hardness measurements were made on the polished cross section of as-sprayed coatings. SEM analysis of the as-sprayed coatings revealed dependence of the coating microstructure on the parameters utilized to deposit the coatings, where certain set of process parameters led to the formation of unmolten/semi-molten splats whereas processing parameters showed fully molten splats. Porosity content of the as-sprayed coatings was measured using image analysis technique. The influence of various spray parameters in both the compositions (Rockit-401 and FeSP586), which yielded coatings with differing microstructures, on the wear performance (erosion and ball on disc) was investigated. Erosion test results indicated that the coating microstructures with minimal unmolten/partially molten splats favoured higher erosion resistance than coatings with unmolten/partially molten splats. SEM analysis of the coatings post erosion test was performed to gain further insights on their erosion behavior. Based on the microstructural and erosion test results, coatings with minimal unmolten splats were chosen for the ball on disc test. Additionally, the wear scars post-ball on disc test were analysed by SEM/EDS and profilometric analysis to gain further insights on the wear behavior and wear loss of HVAF sprayed coatings. In this study, it was shown that Fe-based coatings with delamination free microstructure and low porosity content can be produced by HVAF process. Additionally, it was shown that under certain HVAF processing conditions, coatings with fully molten splats could be achieved. It was also demonstrated that the coating microstructures with fully molten splats had superior erosion performance. SEM/EDS analysis of the coatings post sliding wear test showed the presence of oxides in the coating matrix, which could have been generated during the sliding wear test or during the coating deposition.