Abstract: Aim To study the interface residual thermal stress of plasma sprayed ZrO2- NiCrAl functionally gradient thermal barrier coatings , and to study the effect of thermal barrier coating thickness and of parameter selection on the interface residual thermal stress . Methods Based on thermoelastic assumption, the design of coating structure is fulfilled by use of parameter selection on the The interface residual thermal stress in the functionally gradient thermal barrier coating designed is effectively mitigated. Conclusion The appropriate functionally gradient thermal barrier coatings for the protection of metal substrate can be designed and selected by use of finite element method.