Currently,　the　self-shadowing　effect　of　impinging　particles　is　recognized　as　a　vital　factor　to　form　columnar-like　coating　in　the　manufacture　of　thermal　barrier　coatings.　Most　of　these　quasi-columnar　coatings　are　usually　prepared　under　a　very　low-pressure　condition.　This　paper　investigates　a　novel　quasi-columnar　yttria　stabilized　zirconia　(YSZ)　coating　using　an　atmospheric　plasma　spray-physical　vapor　deposition　method.　The　microstructures　of　the　coating　present　a　quasi-columnar　structure　that　is　distributed　along　the　cross-section　of　the　coating　within　certain　intervals　with　a　large　number　of　cluster-like　structures　on　the　top　surface　of　the　coating.　A　lower　particle　velocity　that　contributes　to　the　generation　of　a　mass　of　vapor　YSZ　materials　is　studied　via　experimental　and　numerical　analyses　and　these　results　are　compared　with　other　current　plasma　spray　methods.　The　mechanism　of　the　self-shadowing　effect　from　impinging　particles　that　leads　to　the　formation　of　a　quasi-columnar　feature　at　the　boundary　layer　of　the　substrate　is　demonstrated　by　a　three-dimensional　numerical　simulation　and　experimental　observation.　Furthermore,　the　hybrid　growth　model　of　the　vapor　and　droplet　co-deposited　coating　is　clarified　in　this　paper.　©　2020　IOP　Publishing　Ltd.