This paper introduced the structure of the high efficiency hypersonic plasma spraying gun and the effects of hypersonic plasma jet on the sprayed particles. The optimised spraying process parameters for several ceramic powders such as Al2O3, Cr2O3, ZrO2, Cr3C2 and Co-WC were listed. The properties and microstructure of the sprayed ceramic coatings were investigated. Nano Al2O3-TiO2 ceramic coating sprayed by using the high efficiency hypersonic plasma spraying was also studied. Compared with the conventional air plasma spraying, high efficiency hypersonic plasma spraying improves greatly the ceramic coatings quality but at low cost.