This paper discusses the effect of several variables in plasma spray method, namely; the flow rate, spray distance and power used on the mechanical properties of Cu-Ni coated A7075. All spraying techniques were designed using 23 factorial plans prior to the actual experiments. The produced coatings were characterised using a scanning electron microscopy (SEM). Morphological observation indicated that most sprayed particles were formed in splash shape splats. The effects of interactions between the response variable factors were screened using a response surface methodology. Three coating factors were used, namely, plasma power, number of coating layer and spraying distance where as the coating hardness and surface roughness were set as the responses. In general, an ideal parameter of 5 coating layers with a power of 30 kW and a spraying distance of 150 mm gave a maximum hardness of 622 Hv and a minimum surface roughness of 9.7 µm.