In the first part of the present study, an appropriate inflow turbulent boundary condition is chosen. Then, a comparison is made between two turbulence models for a plasma jet discharged into air atmosphere. The plasma jet gas phase flow is predicted with the standard k-epsilon model and the RNG model of turbulence. Particles behavior is modeled using stochastic particles trajectories. A validation of the plasma jet model is made by comparison with experimental data. This part of the study shows that the flow features are better predicted with the RNG model. The choice of appropriate boundary conditions seems to be crucial for a better simulation of plasma thermal spraying. Afterwards, computations are performed for projection of Ni particles. It is found that the computed particles velocities and temperatures are also better predicted with the RNG model compared with the k-epsilon model. The second part of this study is concerned with the effect of the substrate movement on the gas flow field. This is performed in order to simulate a realistic coatings process where a relative movement between the torch and the substrate always exists. Three substrate velocities have been used and it is found that the flow fields are affected only very near the substrate wall.