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This paper presents an analytical solution of a coated square hole embedded in an isotropic infinite plate under a remote uniform heat flow. Based on conformal mapping, analytic continuation theorem and the alternation technique, temperature and stress functions are derived in a compact series form. Results of temperature contours and interfacial stresses are validated using the finite element method. The comparison indicates the high accuracy of the proposed method. Numerical results of both the interfacial normal and shear stresses for different properties and geometric parameters of a coated layer are provided in a graphical form. The results indicate that the interfacial stresses are highly dependent on the thermal expansion coefficient, thickness of the coating layer and shape factor of the coated square hole. In conclusion, the interfacial shear stresses exhibit a significant increase at the corners with abrupt geometrical changes, which would cause the delamination of the coating layer system. Furthermore, increasing the thickness of the coating layer and the shape factor results in a higher interfacial stress.

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