The functionality and reliability of coated devices are strongly affected by residual stresses of coatings. The distributions of the residual stresses in Al/316L functionally gradient coatings after the fabrication were simulated by means of finite element analysis in order to prevent spallation and to improve the thermo-mechanical behaviour of the tritium penetration barrier. The effect of compositional exponent

the coatings thickness and the number of graded layers on the residual stresses were discussed. The results showed that the compositional gradient of the coating had an obvious influence not only on the residual stress magnitude at the interface between the coating and the substrate

but also on the location of the stress peak. The residual stresses on the coating surface and at the coating/substrate in- terface decreased with an increased coatings thickness

and decreased with the increasing in the number of graded layers until it reach 9.