A process control chart is proposed for DC plasma spraying process based on the in-flight simulation of the injected states of the particles determined by computational fluid dynamics analysis (via FLUENT V4.3). The chart consists of five regions, i.e., the unmelted, melted, vaporized, escaped, and rebounded, which represent the various slates of the particles at impact on the substrate. The X and Y axes of the chart are particle entry conditions, i.e,, diameter (ranging from 20 to 100 mu m) and injection velocity (between 10 to 50 m/s), respectively. The regions indicate the fate of the particle on impact. A grid-array of (14 x 11) entry conditions is simulated in developing the chart, The proposed chart is aimed at providing a general guideline for plasma spraying process in achieving a thoroughly melted particle on arrival at the substrate to be coated.