Plasma spray forming shows overwhelming advantages in rapid fabricating parts and moulds. The coating microstructure is strongly dependent on the splat morphology and inter-splat contact nature. Therefore,it is necessary to investigate the splat formation mechanism in order to analyze the coating properties. A dynamical process of a single fully molten droplet impacting onto a smooth surface was investigated. At the same time,the interaction between the two molten droplets in the horizontal and vertical directions was also simulated. Finally,the simulations of impact of a molten droplet on an inclined plane and a sharp edge were presented. It is concluded that the relative distance of the two droplets strongly influences the dynamics of the two droplets interaction. The various surface conditions have direct effects on the dynamics of splat formation. When a droplet impacts onto an inclined surface and a sharp edge,the splat morphology changes obviously and the phenomenon of break up is observed.
