The use of computation fluid dynamics (CFD) to model the operation of thermal spray processes has gained interest in the thermal spray community; able to provide an understanding as to how a process functions, and better yet how to make a process work more effectively.  Advancements to the science of modeling now permits the ability to create a comprehensive model of a plasma gun that not only simulates the dynamics of the gas but also the mechanics of arcs, thermodynamics, and entrained particulates to form a nearly complete model of a working thermal spray process.  The arc model includes the magnetic field (Lorentz forces), the interaction of the energy flow in the formation of plasma, and the electrical field potential that determines the arc path in the gas stream.  Work presented includes the methods and procedures used to validate the model to a Sulzer Metco Triplex Pro 200 Plasma Gun and exploration of the operating regime to give an in depth and insightful look into the physics behind the operation of a triple arc cascaded plasma gun.