This study investigates the effects of spray distance (250, 300, and 350 mm) and gun traverse speed (4, 7, and 10 mm/s) in the High Velocity Oxygen Fuel (HVOF) process on the microstructural, crystallographic, and mechanical properties of WC-10Co-4Cr coatings. The WC-Co-Cr feedstock powder consists of agglomerated 1~2 µm primary particles, which inherently promotes the formation of partially molten and unmelted particles during spraying due to heterogeneous internal and external melting behavior. When the spray distance was reduced to 250 mm at a gun traverse speed of 7 mm/ s, the shortened particle flight time resulted in insufficient melting, leading to an increased fraction of unmelted particles and interfacial delamination (9.48 %). As a consequence, poor inter-splat bonding caused a reduction in Almen/bending thickness (90 µm) and an increase in residual stress (0.35 mm). In contrast, at a spray distance of 350 mm, the extended flight time increased particle exposure to oxygen, resulting in a higher defect content (0.872 %). Despite this, stabilization of the jet flow improved particle impact angle and lamellar stacking, yielding the highest bonding strength (77.3 MPa) and hardness (1,400 Hv). Variations in gun traverse speed significantly altered the surface thermal history and splat solidification behavior. Compared with the reference condition (300 mm, 7 mm/s), both slower (4 mm/s) and faster (10 mm/s) traverse speeds produced denser lamellar structures and enhanced splat continuity. At 4 mm/s, localized re-melting and increased binder fluidity reduced porosity but slightly degraded bonding strength due to excessive thermal input. Conversely, at 10 mm/s, suppressed surface overheating and reduced particle scattering led to a more uniform splat structure, accompanied by a slight increase in W2C relative peak intensity and improved bonding strength (74.1 MPa). Overall, spray distance and gun traverse speed are critical parameters governing particle melting, cooling, flight stability, and binder continuity, which collectively determine splat morphology, defect distribution, decarburization behavior, and mechanical performance of WC-Co-Cr coatings.