Abstract: Based on digital image processing theory and finite element mesh generation principle, a methodology to generate the finite element grid model according to the microstructural image of ZrO<sub<2</sub< ceramic coatings is proposed to study thermal barrier coatings. LS-DYNA finite element method is employed to model the crack growth of ZrO<sub<2</sub< ceramic coatings under different tensile stresses. Numerical simulation results showed that based on the true microstructure of ZrO<sub<2</sub< ceramic coatings including defects of voids and micro-cracks, crack grows quickly from the existing defects, leading to the failure of ZrO<sub<2</sub< ceramic coatings. Numerical simulation results agree well with the experimental phenomena.