Mechanical coating properties like hardness, bond strength and tribological features as well as the layer composite lifetime under thermal and mechanical operation stress conditions are mainly influenced by the residual stress situation in the composite. The final residual stress state in thermally spray coated composites is superimposed by different stress mechanisms occurring during the manufacturing process. By means of the micro milling method, residual stresses are measured in a quasi-nondestructive way over the drilling depth. This paper describes the measurement features as well as experimental and numerical results. Measurements are performed on coated plane composite specimens as well as on inside coated bushing guides of aluminum crankcases for different coating materials. The correlation between residual stresses and coating properties is investigated.