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In this study, thermal stresses analysis of ZrO 2 insulation coatings on Cr-Ni substrate during the cooling process was investigated. A transient thermal analysis was performed using finite element method (FEM) via ANSYS software. The temperature versus the time curve obtained from FEM solution was controlled with the temperaturetime diagram measured by a thermocouple. The results obtained from the numerical calculations were improved by the experimental measurement. Additionally, residual stresses were calculated by FEM solutions and they were compared in different points. The compressive and tensile stresses occurred in ZrO 2 coating and Cr-Ni substrate owing to the different thermal expansion coefficients in each material, respectively.