This study is aiming at controlling the microstructure of plasma sprayed Al₂O₃-TiO₂ composite coatings using freeze granulated powders. As sprayed and sintered Al₂O₃ + 3wt%TiO₂ powders were air plasma sprayed with industry process parameters and compared with a commercial powder. The resulting coatings were investigated with respect to powder flowability, porosity and microstructure of the granules. The results showed that microstructure and melting fraction in the coatings could be tailored with the freeze granulation process and heat treatment conditions.