The effects of plasma spray parameters, Hydrogen Flow Rate (HFR) and electric current (I), on the microstructure and erosion resistance of Ni60 coatings were investigated using SEM, XRD, LSCM and erosion wear test machine. Results show that the Ni60 coating is mainly composed of γNi, Ni3B, Cr2B, CrB, M7C3 and M23C6 phases. As HFR and I increase, the lamellar thickness of the coating decreases, while the crystallinity, average grain size, microstrain, residual stress, microhardness and erosion resistance increase. Excessive HFR and I result in the increase in coating porosity and decreases in microhardness and erosion resistance. The Ni60 coating deposited at HFR = 12.5 ft3/h and I = 500 A possesses higher erosion resistance, especially under the condition of small angle erosion.