It　is　quite　important　to　clearly　understand　the　dynamic　process　of　single　splat　formation　for　optimizing　the　plasma　spraying　process.　In　present　study,　a　three-dimensional　model　including　heat　transfer　and　phase　change　was　developed　on　Ansys　Fluent　14　platform　to　simulate　the　impact,　flattening　and　solidification　of　a　molten　droplet　on　a　solid　substrate　during　plasma　spraying.　The　phase,　contact　pressure,　temperature　and　velocity　fields　at　different　spreading　times　were　presented　to　gain　an　insight　into　splat　formation　mechanism.　The　predicted　splat　morphology　was　in　good　agreement　with　the　experimental　photos.　The　effect　of　mushy　zone　constant,　a　parameter　dominating　the　solidification　behavior　of　fluid　in　Fluent,　on　the　flattening　of　droplet　was　further　investigated.　Through　comparing　the　calculated　spread　factor　from　present　model　with　the　experimental　value,　a　mushy　zone　constant　of　108　or　109　was　found　to　be　more　appropriate　for　simulation　on　the　solidification　problem　occurring　in　high-speed　impact　and　flattening　process,　instead　of　the　range　of　104-107　recommended　in　Fluent.　©　2014　Elsevier　B.V.　All　rights　reserved.