Surface engineering plays an essential role in enhancing high pressure turbines performance, which work under severe thermal and mechanical conditions. Thermal Barrier Coating (TBC) system is economically demanded for efficient, environmental friendly and extended gas turbine life. The recent study intends to extend TBC life, which exposed to cyclic loading conditions. An intermediate α-Alumina layer was deposited by sol-gel on APS-CoNiCrAlY bond layer surface, which was deposited on Ni-superalloy substrate. APS-YSZ was deposited as ceramic top coat on the top of alumina layer. The thermal behavior of the modified TBC system was compared with the standard one after 40, 80 and 160 thermal cycles at 1150 °C using optical microscopy, Scanning Electron Microscopy (SEM) equipped by Energy Dispersive X-ray analysis (EDS), X-ray Diffraction (XRD) and Raman spectroscopy. The effect of the intermediate layer on the residual stresses generated in ceramic layer during operation was studied. The oxidation kinetics were evaluated by measuring cracks lengths within ceramic layer and measuring Thermally Grown Oxide (TGO) layer thickness. Experimental evidence was gathered showing that the presence of the interlayer Al2O3 layer has potential to reduce cracks lengths and TGO thickness by suppressing the formation of detrimental oxides. The Al2O3 layer acts as a barrier for oxygen diffusion. This effect improves the oxidation resistance of metallic CoNiCrAlY Bond, hence increases TBC lifetime.