Abstract: Thermal barrier coatings (TBCs) are one of the core technologies that ensure the service of high-performance aero-engine turbine blades, rocket engines thrust chamber walls, and other advanced equipment in extreme high-temperature environments. However, accurately calculating the structural thermo-mechanical coupled field re-mains challenging due to the interface complexity and discontinuity in TBCs. Aiming at the bottleneck prob-lems such as poor convergence and low efficiency existing in the analysis of interface discontinuous fields by traditional numerical methods, this paper proposes a refined calculation method for the thermo-mechanical cou-pled field of TBC structures using the Green's function. Based on the general solution of the material, a concise harmonic function containing undetermined constants is constructed and substituted into the general solution. The undetermined constants are determined by boundary conditions, interface conditions, and thermo-mechanical equilibrium conditions. This yields a comprehensive analytical solution for the thermo-elasticity of TBC structures. Based on the solution, the sensitivity analyses of parameters such as coating thickness and thermal expansion mismatch effect were systematically carried out, revealing the influence laws of coating thickness and thermal parameter mismatch on the interfacial stress field. This provides a theoretical foundation for the precise design of TBC structures and the study of interface failure mechanisms.

Key words: Thermal barrier coatings, Double-layer coating, Thermal stress, Green’s function, Transversely isotropic