Al2O3 coating is deposited using a low power plasma torch with a novel hollow cathode through axial powder injection under a plasma power up to several kilowatts. The effects of the main processing parameters including plasma arc power, operating gas flow and spray distance on particle velocity during spraying, and the microstructure and property of the coating are investigated. The microstructure of the Al2O3 coating is examined using optical microscopy and X-ray diffraction analysis. The property of the coating is characterized by dry rubber wheel abrasive wear test. The velocity of in-flight particle is measured using a velocity/temperature measurement system for spray particle based on thermal radiation from the particle. The dependency of the microstructure and property of the coating on spray particle conditions are examined by comparing the particle velocity, and microstructure and abrasive wear weight loss of subsequent coating deposited by low power plasma spray with those of the coating by conventional plasma spray at a power one order higher. X-ray diffraction analysis of the coating revealed that Al2O3 particles during low power plasma spraying reach to sufficiently melting state prior to impact on the substrate with a velocity comparable to that in conventional plasma spraying. The experiment results have shown that processing parameters have significant influence on the particle conditions and performance of deposited Al2O3 coating. The coating of comparable microstructure and properties to that deposited by conventional plasma spray can be produced under a power one order lower. From the present study, it can be suggested that a comparable coating can be produced despite plasma power level if the comparable particle velocity and molten state are achieved. (C) 2003 Elsevier B.V. All rights reserved.