The subcommittee on superalloys and coatings, The Society for Materials and Science, Japan (JSMS) was established in 1997. As second stage of the committee, we investigated a fundamental study on thermal plasma sprayed thermal barrier coatings (TBCs). Especially, relationships between spray conditions and coating properties are discussed. It was used 4 spraying conditions such as 1) standard condition, 2) larger particle used and lower velocity, 3) normal particle used and lower velocity, and 4) standard condition and heating up the substrate to 473K. As a round robin test, porosity ratio, residual stress, and bonding strength were evaluated by several techniques for the specimens, which were sprayed by above 4 conditions. As a result, Young’s modulus, and tensile strength increased with decreasing porosity ratio. In case of tests for residual stress evaluation, as-sprayed specimens have small tensile residual stresses. After thermal exposure, residual stresses shifted to compressive.