In order to achieve better knowledge of the thermal barrier coatings (TBCs) by supersonic atmospheric plasma spraying (SAPS) process, an experimental study was carried out to elaborate physicochemical properties of particles in-flight during the SAPS process. One type of commercially available agglomerated and sintered yttria-stabilized-zirconia (YSZ) powders were injected into the SAPS plasma jet and collected by shock chilling method. The YSZ particles in-flight physicochemical properties of the melting state, morphology, microstructure, particle size distribution, element composition changes and phase transformation during the SAPS process have been systematically analyzed. The melting state, morphology and microstructure of the collected particles were determined by scanning electron microscopy (SEM). The particle size distribution was measured by a laser particle size analyzer (LPSA). Element compositions were quantitatively analysed by an electron probe X-ray microanalyzer (EPMA). Additionally, the X-ray diffraction (XRD) method was used to analyse the phase transformation. The results showed that the original YSZ powders injected into the SAPS plasma jet were quickly heated and melted from the outer layer companied with breakup and collision-coalescence. The outer layer of the collected particles containing roughly hexagonal shaped grains exhibited a surface texture with high sphericity and the inside was dense with hollow structure. The median particle size was decreased from 45.65 μm to 42.04 μm. Besides, phase transformation took place and the content of zirconium (Zr) and yttrium (Y) element was decreased with the evaporation of ZrO2 and Y2O3.