Abstract: In order to meet the needs of prolonging the life of a blast furnace, a cast iron cooling stave with high performance was developed. The thermal boundary condition of the cast iron cooling stave with surface-alloyed cooling water pipes for numerical simulation of temperature field was determined by the use of hot test data. The commercial software ANSYS and the heat-structure coupling method were used to analyze the influence of furnace temperature, slag crust, edge contact pressure on the thermal stress and thermal deformation of the cast iron cooling stave under high-temperature condition. Effective measures were used to reduce the thermal stress of the cooling stave and control its thermal deformation. The new concept of high cycle heat loading, which evaluates the cooling capacity of cast iron cooling staves, was presented based on the strength analysis theory of spheroidal graphite iron.