Recently, thermal spraying of micro-sized particles in suspension has become a field of high importance for producing dense coatings with enhanced properties compared to such of thermal sprayed coatings with nano material. On the one hand, larger particles have obviously the advantage of a higher momentum compared to nano particles but on the other hand, the larger particles has a negative influence on the sedimentation stability. To overcome this negative side effect the sedimentation behavior of an Al2O3 suspension with a scheduled average particle diameter of d50 H 1.4 µm was produced and analyzed. For the coating experiments, a GTV Top Gun SS System (HVOF) with axial injection was used. The process parameters (C2H4/O2 flow, feed rate etc.) were varied over a wide range. To pretend sedimentation, a rheology additive was added to suspension for producing a thixotropic flow behavior. The goal was generating a stable suspension under static conditions and fluid behavior under shear strain. Therefore, dynamic viscosity over a share rate of 0.1 s-1  1000 s-1 was measured for three different additive concentrations. Low concentration of additive, (0.6 m. %), gives a sufficient stability and relatively low viscosities at high shear rates. The sedimentation stability was proved by oscillation rheology. The experiments showed that adhesive coatings can be produced with low feed rates of 20 ml/min. The coatings with the lowest porosities were obtained with low feed rates and high ethylene flows (100 l/min). The deposition efficiency decreased substantial when a combination of low oxygen and ethylene gas flows was chosen. Overall hardness values of 800 HV were obtained for coatings with the most suitable process parameters. The low hardness implicates a significant amount of ³-Al2O3. To determine the phases XRD analyses are scheduled. To enhance the homogeneity and properties of the coatings further approaches will be done.