Abstract: In this paper, a new analytical model, which can be used to deal with the residual stresses distributions in the processes of quenching and cooling, is presented with the consideration of effects of porosity and temperature gradient in the coating. Firstly, the distributions of porosity and temperature along the thickness are obtained by computer simulation of the deposition of heated particulates with the new model, the effects of thermal expanding coefficients, Young's modulus, temperature of substrate, etc., on the changing of residual stresses are investigated. It is found that the increase of the cooling temperature and the enlargement of the difference of expanding coefficients between substrate material and coating ceramic can reduce the tensile residual stress in the coating layers and prevent efficiently the coating from failing.