The thermal stresses in room and elevated temperatures were studied in thermal barrier coatings (TBCs) which was coated at the outer surface of pipe specimens, using finite element method (FEM), and the Walker viscoplastic theory was adopted to depicting the stress-strain constitution in the ceramic layer. During the design of FEM analysis computation, the orthogonal design method widely used in experiment study, was used, and the contributions of four factors to the being of thermal stress were achieved. The results show that the four factors have the remarkable effect to thermal stress in TBCs, and the factor of thermally grown oxide is the most important, the stress changing rules of four factors are different in TBCs with the ascending of levels.
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