Abstract: The Fe-Cr-B-Si and Fe-Cr-B-Si-Mo coatings of various thickness were separately deposited by highefficiency plasma spraying technology(HEPS),detonation gas spray(DGS)and high velocity arc sprayingtechnology(HVAS).Surface residual stress of these coatings was measured by an X-ray stress tester,and therelation curves between residual stress and coating thickness were obtained.Further more,distributing wave forresidual stress along thickness direction was measured by the X-ray stress tester and electro-analysis method.Correlation between the residual stress and microstructure of the remanufacturing coatings was investigated by usingX-Ray diffraction,Nano-tester and SEM.Results demonstrated that surface residual stress of coatings was mainlyinfluenced by sprayed materials,methods and parameters,and had correlation with microscopic characteristics ofcoating and not with coating thickness.