In this paper, effect of top-layer thickness on residual stressess of plasma-spraying DCL coating of Sm2Zr2O7 and YSZ was studied by FEM. Results show that Radial stresses in DCL TBCs have similar distributions along horizontal distance which decrease gradually with increasing top-layer thickness. Radial stresses at YSZ layer/ bonding layer remians compressive stress state which is helpful to increase bonding strength the TBCs. Shear stresses transform gradually from tensile stress state to compressive stress state along horizontal distance, and they increase with increasing top-layer thickness. Axial stresses at top-layer/YSZ layer interface increase gradually with increasing top-layer thickness, however, axial stresses at YSZ layer/bonding layer interface were almost not effected by top-layer thickness.