WiththemodifiedAlmenmethod,theforminganddevelopmentprocessofresidualstressinathermalsprayedcoatinghasbeenobtained.Thetestresultsidentifythattheresidualstressinacoatingisdependoncoatingmaterialproperties,techniqueandcoatingthickness.Thepaperpaysmuchattentiontothehysteresisbetweenthecoatingtemperatureandresidualstressinthecoatingorbetweentheappliedstressandthestrainofthecoating,andconfirmsthatthefactisresultedfromthe"GasFix"characterofathermalsprayedcoating.