Low pressure cold gas dynamic spray (LPCGDS) is a coating process that utilize low pressure gas (5–10 bars instead of 25–30 bars) and the radial injection of powder instead of axial injection with the particle range (1–50 μm). In the LPCGDS process, pressurized compressed gas is accelerated to the critical velocity, which depends on length of the divergent section of nozzle, the propellant gas and particle characteristics, and the diameters ratio of the inlet and outer diameters. This paper presents finite element modeling (FEM) of powder stream in supersonic nozzle wherein adiabatic gas flow and expansion of gas occurs in uniform manner and the same is used to evaluate the resultant temperature and velocity contours during coating process. FEM analyses were performed using commercial finite volume package, ANSYS CFD FLUENT. The results are helpful to predict the characteristics of powder stream at the exit of the supersonic nozzle.