Electric are spraying with dual wires is an economical coating process finding diverse applications. Electrode phenomena, such as oxidation and turbulence have strong effects on the droplet formation, therefore on the coating properties. Low turbulence intensity of an atomizing gas flow can be related to higher frequency and smaller amplitude of the are voltage fluctuations. Nitrogen reduces oxidation and turbulence at the electrode region. A converging-diverging nozzle provides higher gas velocity with less turbulence. These operations lead to coatings with lower oxidation and lower porosity.