The ablation and thermal insulation performance of ZrO₂ thermal barrier coating with several different process under combustion conditions of the hydroxyl-terminated polybutadiene propellant was studied. By the orthogonal experiment, the primary and secondary relations between the influence factors (matrix-thickness, adhesive-layer type, surface-layer type and surface-layer thickness)with the ablation and thermal insulation performance of ZrO₂ thermal barrier coating were revealed. And the result of this work would provide a design basis for the application of ZrO₂ thermal barrier coatings to the field of solid rocket motors.