The plasma sprayed deposit consists of individual splat lamellae formed from melted and re-solidified particles which are connected together by mechanical and chemical bonding. The inter-lamellae boundaries are also associated with significant porosity which depends on the thermal spray process parameters. Therefore, the physical and mechanical properties of such deposits are mainly depending on the morphology of individual splats, Adhesion between the deposited structure and substrate, cohesive strength between the splats, the size, morphology, and distribution of pores, cracks and defects, and less on the microstructure within the splats themselves. The morphology of a single splat of ZrO₂ 8Y₂O₃ and also the deposited microstructure under atmospheric plasma spray (APS) conditions were investigated using both numerical simulation and experimental observations. Single splats of two different sizes (-25 um and +25/-45 um) of the commercially used ZrO₂ 8Y₂O₃ powder have been collected on the polished stainless steel substrate at three temperatures (Room, 300 ºC, and 600 ºC). The plasma torch-substrate distance was kept at 50 and 100 mm. The splat morphology and diameters, satellite particles, splat curl up, and splashing behavior were investigated using scanning electron microscope and image analyzer software. The splat/substrate interface was investigated using focused ion beam to cut the cross section of the splat. A three-dimensional model of droplet impact, free-surface fluid flow, and solidification has been employed to investigate the possibility of splashing during droplet impact, the solidification behavior, and the final morphology of a single particle of ZrO₂ 8Y₂O₃ under atmospheric plasma spray conditions. The numerical results were compared with the experimental observations of the behavior of droplets with the same in-flight droplet characteristics such as droplet temperature, velocity, and size. Droplet impact conditions were measured using DPV 2000 instrument. Experimental observations showed no evidence of interface boundary at the splat/ substrate contact area at 300 ºC substrate temperature and 100 mm torch-substrate distance conditions. Numerical simulation and experimental results confirmed that the lowest level of splashing resulting in pancake morphology of splat can be obtained at substrate temperature of 300 ºC at 100 mm torch-substrate distance.