The effects of the coating thickness on the thermal stability of thermal barrier coatings (TBCs) were investigated using furnace cyclic thermal fatigue (FCTF) tests. A bond coat with a double-layer structure was deposited on stainless steel (SUS 304) using a high-velocity oxygen fuel (HVOF) and air plasma spray (APS) method with Ni-Cr-based MCrAlY feedstock powder. The top coat was applied onto the bond coat using APS with yttria-stabilized zirconia (YSZ). After a FCTF test at 1100 ℃ for 1143 cycles, the microstructure in the TBCs specimen showed a good condition without cracking and delamination. In contrast, the bond coat was partially oxidized, and a thermally grown oxide (TGO) layer was observed at the interface between the top and the bond coats. For TBCs with a thinner top coat and a thicker bond coat, a thicker TGO layer was formed. However, increasing the thickness of the top coat decreased the bond coat thickness.