Thermal spray coatings are affected by various parameters. In this study, the finite element method with volume of fluid (VOF) procedure is used to investigate the deposition process which is very important for the quality of sprayed coatings. The specific heat method (SHM) is used for the solidification phenomenon. A comparison of the present model with experimental and numerical model available in the literature is done. A series of numerical calculations is carried out to investigate the effect of the surrounding gas temperature on the splat formation. The variation of the surrounding gas temperature has a significant effect on splat morphology and can affect the adhesion of the splat on the substrate. (c) 2010 Elsevier B.V. All rights reserved.