The aim of this paper was to study the melting conditions of commercial yttria stabilised zirconia (YSZ) powder in high velocity air plasma jet. By means of calorimetric probe, the cross-section of outlet jet velocity and temperature profile were measured. The study covers investigations how the spray regime affects the microstructure of obtained YSZ films by using different shapes of plasma torch anode exit mode: Laval-like contour and cylinder. Outlet plasma flow parameters are discussed with respects to melting states of YSZ powder, anode exit mode and coating qualities of deposited films. The results showed plasma torch shape and started powder characteristics to be the most important parameters influencing the film microstructure.