Abstract: The distribution of residual stresses within the thermal sprayed coating is one of the important factors affecting the quality and performance of the coating. In this paper,based on the assumption of layer-by-layer forming during thermal spraying process,a two-dimensional numerical model was proposed to analyze the temperature and stress fields for aluminum coating deposited on a metallic shaft part substrate. The simulation results show that a wave-like rise of the temperature in the coating occurred and a great amount of hot particles individually cooled rapidly. The distribution of residual stresses in the coating was also investigated,and it was found that the circumferential and axial stresses are tensile and far higher than that of the radial stress,while the radial stress could be tensile or compressive. As the spraying was proceeding and the coating was thickening, the residual stress on the deposited layer was partly offset by the followed layers,and the components of the residual stresses increased with the coating thickness.