Abstract:Cu ,Ti ,Al and Ti powders with diameters of several tens micrometer were thermally sprayed onto mirrored stainless steel SUS304 substrates by atmospheric plasma spraying .Through observation on the top surface and cross section morphologies of the individual splat collected on the substrate surface ,the effect of powder materials on splat formation process was generally investigated .According to the result , Cu and Fe depositions on the substrate exhibited as typical splash splat ,and Al depositions showed slightly splashing ;On the other hand ,Ti particle deposited as regular disk-shaped splat with significant micro-cracks .