The depletion of conventional fuel sources at a tremendous rate and increasing environmental pollution has motivated extensive research and development in the combustion chamber of the engine. In the present study, multilayer ceramic coating on the piston crown was developed to improve thermal efficiency, combustion and exhaust emission, fuel consumption. Also, ceramic coating on crown withstands the elevated temperature and pressure and provides maximum working efficiency. The property advantages of Alumina and Yttria Stabilized Zirconia in combination were utilized to fabricate the Thermal Barrier Coating (TBC) in this study. The multilayer coating of alumina and zirconia was fabricated using an air plasma spray method. For effective bonding, a Ni-based bond coat was applied on the substrate before TBC topcoat. A research piston similar to the actual piston was used to fabricate TBC coating. Microstructural characterization was carried out to check the coating uniformity using Optical and Scanning Electron Microscope. The defect-free uniform coating was formed with an average thickness of bond coat, alumina and YSZ was about 90 µm, 70 µm, and 180 µm respectively. The performance of the TBC coating on the crown of the research piston was assessed by subjecting to the thermal barrier and thermal shock tests. In the thermal barrier test, a maximum temperature drop of 265 °C was observed at 590 °C. Delamination of the bond coat was observed after 90 cycles. Microstructural analysis was also carried out to study the damage that occurred during thermal exposure. All the observation and the test results of this investigation are reported here.