A three-dimensional computational model is used to simulate the in-flight particle melting behavior during plasma spraying process. The stochastic model is used for the particle size distribution. The particles surface temperature distributions at various spray distances have been presented. The results show that the surface temperature distribution varies with the spray distance. Single peak to double peaks and back to single peak has been observed in the simulations and also in the experiment. The effects of particle size and its distribution and plasma composition on the pattern shift have been investigated. Understanding the pattern shift may enable the design of a good control indicator to determine the particle melting status.