Thermal spray processing of functionally graded materials requires that the spray patterns of different particle types coincide at impact and that each particle type arrives with the appropriate temperature and degree of melting. Measurements of particle velocity, temperature, and size along with spray pattern characteristics have been obtained for co-injected NiCrAlY and zirconia powder. The plasma and particle flow fields were also simulated with a pseudo 3-D model using the LAVA computer code. The model assumes that the gas flow is axisymmetric while the particles are treated in a fully 3-D manner. A stochastic discrete-particle model that includes turbulent dispersion dictates particle behavior. The simulation produced reasonably accurate velocities and particle trajectories, although, particle temperature is consistently over predicted. Comparisons between the calculated and measured velocity and temperature statistical distributions and calculated molten fractions are discussed.