An experimental investigation was undertaken to study the Cobalt-based Stellite 6, powder deposited on SS 304 stainless steel substrate without any intermittent layer using an atmospheric plasma spray deposition process by varying the thickness of coating in the range of 74 µm, 128 µm, and 215 µm. The effect of coating thickness on metallurgical properties and corrosion resistance behavior was investigated. Optical microscopy, Scanning Electron Microscopy (SEM), and Energy Dispersive X-ray Spectroscopy (EDS) were employed to study the morphology of Stellite 6 coating. X-Ray Diffraction was used for structural analysis and to identify the phase formation. It was observed that the sample with 128 µm coating thickness provides the best result concerning microhardness and microstructure characteristics whereas the sample with 215 µm coating thickness provides the best corrosion resistance property. The reasons for the deviation were investigated and the factors responsible for the deviation were assigned in this investigation.