The particle size of powders for thermal spraying was measured by dry sieving method, laser diffractionmethod and scanning electron microscopy method. The effect of the powder morphology on the particle size testresults was studied by comparing the test results between different methods. The result shows that the particle sizedistribution of spherical powder, irregular powder and flake powder measured by dry sieving method exhibits goodrepeatability. The results of the three test methods are huge different, and the larger the particle size, the greaterthe difference.