The work aims to study factors affecting blocking of air film cooling hole during preparation of thermal barrier coating by plasma-spray physical vapor deposition. With agglomerated and sintered ZrO2-7wt%Y2O3(7YSZ) powder as raw material, thermal barrier coatings were prepared by plasma spray-physical vapor deposition (PS-PVD) on superalloy plate substrate with precast air film cooling holes. Effects of parameters including hole angle and pore size of the air film cooling hole on hole blockage were studied. When pore size of the air film cooling hole was controlled within 0.85 mm, shrinkage factor of the pore size was 19.01%, 14.50%, 14.86%, respectively at the angle of 30°, 60°and 90°. Shrinkage factor of the pore size decreased and maintained stable after a while as the angle increased. Both coatings outside and inside the hole were of columnar structure. When the angle of air film cooling hole was 30°, shrinkage factor of the pore size was 36.40%, 31.70% and 24.45%, respectively provided with pore size of 1.0 mm, 1.3 mm and 1.5 mm. The shrinkage factor decreased while distribution depth of the coating in hole increased as the pore size increased. The angle of air film cooling hole will influence deposition efficiency of thermal barrier coatings, and thus affecting shrinkage factor of pore size. Pore size of the air film cooling hole has no effect on deposition efficiency of thermal barrier coatings, but it will affect shrinkage factor of pore size.