The effect of NiCoCrAlYx-ZrO2 (1-x) interlayer on the residual stresses in the ZrO2/NiCoCrAlY thermal barrier coating due to thermal cycling was analyzed using the finite element method. Modeling results showed that the magnitude and distribution of the residual stresses in the coating were strongly influenced by the material combination characterized by the value of x and the thickness of interlayer. The maximum tensile stresses at the different regions (i.e. coating/substrate interface, coating surface, et al.) as functions of the material combination and the thickness of the interlayer were obtained. The. physical meaning of the above results was also discussed.