The effects of nozzle configuration on the characteristics of flow inside DC arc plasma torches are investigated by numerical simulation. The plasma torches with three typical types of nozzle configuration are used in this paper, and these torches are the SG-100 series commercial products of PRAXAIR Thermal Spray Products Inc. The assumption of steady-state, axis-symmetric, local thermodynamic equilibrium, and optically thin plasma is adopted in a two-dimensional modeling of plasma flow inside a plasma torch. The PHOENICS software is used for solving the governing equations, i.e., the conservation equations of mass, momentum, and energy. The calculated arc voltages are consistent with the experimental results when arc current, gas inflow rate, and working gas are the same. Temperature, axial velocity contours inside the plasma torches, and profiles along the torch axis and at the outlet section are presented to show the plasma flow characteristics. Comparisons are made among these torches in detail and the results show that torches with different anode nozzle configurations produce different characteristic plasma flows.