In the kinetic spraying process, the critical velocity is an important criterion which determines the deposition of a feedstock particle onto the substrate. It was experimentally and numerically proven that the critical velocity is determined by the physical properties and the state of materials such as initial temperature, size and the extent of oxidation. Compared to un-oxidized feedstock, oxidized feedstock required a greater kinetic energy of the in-flight particle to break away the oxide film during impact. The oxide film formed on the surface of particle and substrate is of a relatively higher brittleness and hardness than those of general metals. Because of its physical characteristics, the oxide significantly affected the deposition behavior and critical velocity. The effects of oxidation on the critical velocity and the deposition behavior of the feedstock were investigated and evaluated by individual particle impact tests in this study. The velocity of pure Al particles was measured for a wide range of process gas conditions.