In the present study, a novel gas multiple-tunnel plasma spraying technology was adopted to fabricate amorphous Fe-based composite coatings with various contents of ZrO₂. By this way, the ZrO₂ particles were distributed homogeneously in the matrix and the proportion of the two phases in the composite coatings can be regulated. During the wear process, the wear resistance is improved for the composite coatings. Meanwhile, the introduction of ZrO₂ improves both the corrosion resistance and porosity. Therefore the best corrosion resistance is obtained for the composite coating with 50% ZrO₂.