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In-situ nanostructured FeAl2O4 composite coatings were prepared by plasma spraying Al/Fe2O3 composite powders using different spraying powers.The effects of plasma spraying powers on microstructure and property of FeAl2O4 composite coatings were investigated.The results indicated the composite coatings had the microstructure with thin lamellar splats rich in FeAl2O4 as matrix, and dispersed granules rich in Fe and thin lamellar splats rich in Al2O3 as second phases.The reaction degree of Al/Fe2O3 composite powders increased from spraying power of 25 KW to 30 KW and then decreased from spraying power of 30 KW to 40 KW, which resulted in that the Al2O3 content increased firstly and then decreased.The coating prepared by spraying power of 30 KW had the maximum microhardness, which was attributed to the maximum Al2O3 content presented in the coating and the most uniform microstructure of the coating.