The work aims to study the influence of different preparation parameters on the residual stress of aluminized lay-er/ZrO2 composite coating. Workbench module in ANSYS 18.1 software was used to generate residual stress under different preparation parameters in the deposition process with thermal mechanical coupling. As the holding time increased from 2 h to 5 h, the equivalent stress decreased from 895 MPa to 862 MPa; As the deposition temperature increased from 400 ℃ to 700 ℃, the equivalent stress is increased from 541 MPa to 999 MPa; As the thickness of ZrO2 layer increased from 2 μm to 14 μm, the equivalent stress decreased from 925 MPa to 835 MPa, but the shear stress at the interface of aluminized layer and zirconia layer increased from 59 MPa to 101 MPa. The change of the thickness of the substrate had little effect on the thermal stress in the substrate and the aluminized layer, but had a great influence on the ZrO2 layer. As the thickness of the substrate increased from 0.3 mm to 0.8 mm, the equivalent stress increased from 745 MPa to 850 MPa. The aluminized layer reduced the equivalent stress from 877 MPa to 745 MPa, the radial stress decreased from -1235 MPa to -1022 MPa, the shear stress decreased from 105 MPa to 89 MPa, and the axial stress decreased from -375 MPa to -312 MPa. The axial stress in the ZrO2 layer changed significantly from -128 MPa to -39 MPa. Increasing the aluminizing holding time can reduce the stress of the whole composite coating; The greater the difference between the deposition temperature and the room temperature is, the more serious the thermal matching imbalance is; As the thickness of the ZrO2 layer increases, the stresses of the matrix and the aluminized layer increase, and the stress in the ZrO2 layer decreases slightly except for the shear stress. As the thickness of the substrate increases, the equivalent stress and radial stress of the ZrO2 layer increase significantly, and the thickness of the substrate decrease. The aluminized layer plays a good buffering role.