The quality of coatings is directly influenced by the flattening and solidification of many
individual molten droplets in plasma spray forming, so many properties such as thermal, electrical,
mechanical etc are strongly linked to the real contact between the “piled-up” splats. The research on
the transient temperature of impacting droplets and the heat transfer between droplets and substrate
plays an important role in improving the quality of coatings. Because of complexity and high cost of
temperature measurement systems for molten droplet during flattening in plasma spray forming at
present, this paper presents a new kind of simulation measurement system for transient temperature of
spray droplets when impacting on substrate based on LabVIEW, which could display the real-time
changes of the temperature by waveform graph. Finally, the experiments were carried out on Pb-Sn
alloy molten droplets to reveal the close connection between the impacting droplets temperature
changes and the coatings quality, and the heat transfer between droplets and substrate was discussed.
