Arc-voltage feedback PID ( Proportional plus Integral plus Differential) controller and arc-current feedback PID controller are designed with an algorithm of discrete PID. In order to realize parameters optimization and adaptation of the arc-spraying process and to reduce blindness in selecting process parameters, a serial communication interface between PC and MCU (Micro Control Unit) is designed so that on-line modification of the PID control parameters is implemented. A genetic algorithm is adopted to optimize PID control parameters. Meanwhile, the error between the actual value and the setting value of spraying current is selected as the judgment criterion to determine the adaptability for the algorithm. The best optimal population of PID control parameters can be obtained, so that the optimal controlling in arc-spraying process is realized and an excellent coating of arc-spraying is obtained.