NiCrAlY bond coat was prepared by HVOF (high-velocity oxygen fuel) spray on nickel-based superalloy. Surface treatments like grit-blasting, shot-peening and vacuum treatment methods were carried out in order to study the effects of surface modification on thermal cycling lifetime of TBCs. The surface-modified TBCs exhibited better thermal shock resistance. Failure of TBCs with the as-sprayed bond coat occurred within the top coat and at the interface between spinels and the top coat, while that of after shot-peening, grit-blasting and vacuum treatment occurred mainly within the top coat. TGO (thermally grown oxide) formed on as-sprayed bond coat was composed of a Ni(Al,Cr)2O4 spinels outer layer and a Al2O3 inner layer. But, a continuous and uniform Al2O3 formed after surface modification. Formation of the mixed oxides (spinels) on the as-sprayed bond coat accelerated the failure of TBCs. NiCrAlY bond coat was prepared by HVOF (high-velocity oxygen fuel) spray on nickel-based superalloy. Surface treatments like grit-blasting, shot-peening and vacuum treatment methods were carried out in order to study the effects of surface modification on thermal cycling The surface-modified TBCs supports better thermal shock resistance. Failure of TBCs with the as-sprayed bond coat occurred within the top coat and at the interface between spinels and the top coat, while that of after shot-peening, grit -blasting and vacuum treatment occurred mainly within the top coat. TGO (thermally grown oxide) formed on as-sprayed bond coat was composed of a Ni (Al, Cr) 2O4 spinels outer layer and a Al2O3 inner layer. Formation of the mixed oxides (spinels) on the as-sprayed bond coat accelerated the failure of TBCs.