Titanium alloys are used as biomaterials coated by thermal spraying due to its shape memory alloy property and superior surface characteristics. Thermal spray coating is done at high temperature leading to residual stresses. Literature indicates that coating thickness is an important parameter for thermal and impact stresses that induce residual stresses and this study attempts to quantify the relationship between them. Impact and transient thermal cases are solved simultaneously and the computed equivalent stresses are residual stresses. The Substrate for the present work is Ti-6Al4V and coating materials are Yttria-Stabilized-Zirconia(YSZ), Hydroxyapatite(HA) and Mixture of both HA with 10% to 50% of YSZ with drop sizes varying from 50 to 100 micron diameter. Fluid Structure Interaction(FSI) study is solved using LS DYNA. Residual Stresses are computed for each case and compared among different coating combinations. As expected, as drop size increases, residual stresses also increase. Results from this study show residual stresses are maximum for YSZ for respective drop size whereas it is minimum for Pure HA. As amount of YSZ increases in mixture of HA and YSZ, residual stresses generated are in the higher side. These results are important for coating various orthopedic implants to vary rigidity and toughness. © 2017 Society for Biomaterials and Artificial Organs - India. All rights reserved.