To understand the effects of spray parameters on the splashing, cast iron particles were plasma-sprayed onto polished surfaces of aluminum substrate to form single splats. Various plasma arc powers and spray distances were applied to adjust the morphology of the splats which was studied using a ifeld emission scanning electron microscope (FESEM). The experimental results showed that the splashing of impinging droplets was significantly restrained for the splats deposited with high arc power (30 kW) and short spray distance (80 mm). This ifnding would be beneifcial to improving the adhesive strength of the coating.