Abstract: The formation of plasma sprayed molybdenum splats on 1Cr13 stainless steel and H70 brass substrate was simulated by three dimensional transient modeling based on the finite volume method, using the volume of fluid method (VOF) to track the free surface of droplet and considering the flow coupled with heat transfer and substrate melting. The molybdenum splats were prepared on the substrates by plasma spraying and the morphology and profile curves of the splats were tested by scanning electron microscope and step profiler respectively. The experimental results were compared with those of simulation. The results show that the morphology, thickness, spreading factor of splats and substrate crater depth obtained from modeling agreed well with experimental results. The spreading periphery of molybdenum droplet was lifted over the 1Cr13 steel substrate due to the obstacle of solidified layer, and then the periphery separated from the solidified layer and formed the splashing of molybdenum droplet on 1Cr13 stainless steel.