Abstract: NiCoCrAlY powders was prepared by plasma rotating electrode process (PREP), vacuum gas atomization (VGA) and agglomeration-sintering method (ASM), respectively. The particle size distribution, oxygen content (mass fracion), porosity, and particle shape of these three NiCoCrAlY powders were analyzed. The results indicate that the powders prepared by the plasma rotating electrode process exhibit the most regular particle shape, the best distribution of particle size, and the lowest oxygen content and porosity, making them highly suitable for the high-precision additive manufacturing and high-performance coatings. The powders produced by vacuum gas atomization show a relatively uniform particle size but contain a small fraction of non-spherical particles. The oxygen content and porosity are slightly higher, making them more suitable for the large-scale industrial applications. In comparison, the powders produced by agglomeration-sintering exhibit a moderate porosity but a strikingly uneven distribution of particle size, and an extremely high oxygen content, putting the applications only in where low-quality requirements and the cost control are prioritized, such as the production of large-particle powders or composite powders.