A multi-physics model is developed to investigate the thermal stresses in a micro-tubular SOFC, based on a previously developed thermal-fluids model predicting cell operation. Mechanical properties of the anode and cathode are determined theoretically through composite structure approximation. Residual stresses arisen during the fabrication of the cell due to the mismatch in thermal expansion coefficients are calculated by accounting for each fabrication process separately. The interactions between the cell, the sealant and the alumina tube are accounted for a better representation of the actual fuel cell test setup. The effect of sealant and alumina tube on the stress distribution in the cell is investigated and it is found out that near the fuel cell-sealant interface stress distribution changes significantly. The effect of spatial temperature gradient on the stress distribution is also analyzed and found to have a minimal impact for a typical fuel cell operation at mid-range current densities. The effects of oxygen vacancies caused by the reduction of the GDC electrolyte on the overall stress distribution are also shown. Oxygen vacancies of the electrolyte result in relaxation of the stresses due to the alleviation of mismatch in Young's modulus between different layers of the cell. (C) 2010 Published by Elsevier B.V.