<p>Metal friction is ubiquitous in engineering applications, and its effects on energy dissipation, interface damage, and structural failure have a significant impact on the performance and reliability of engineering systems. This paper systematically reviews recent advances in the thermo-mechanical analysis of metallic friction interfaces. Based on the interaction between thermodynamics and mechanics, it analyses the theoretical framework of multi-physics coupling analysis of metallic friction interfaces and presents the development history of thermo-mechanical coupling models. By deconstructing the fundamental theoretical framework of tribology, this study focuses on revealing the dynamic evolution laws of thermal effects at interfaces, summarising the microscopic mechanisms of friction-induced heat generation, the influence patterns of heat conduction mechanisms, and the distribution characteristics of three-dimensional temperature fields. Furthermore, by integrating the theory of elastic–plastic mechanics, this study characterises the distribution of thermal stresses and the dynamic response characteristics of thermal deformation, elucidating the regulatory mechanisms of the temperature field-stress field coupling effect on interface mechanical properties. Through critical analysis, this study identifies the limitations of current models in characterising dynamic loads and phase transition effects, and explores the synergistic application of multi-scale simulation and intelligent sensing technologies to provide new insights for optimising interface performance.</p> Graphical abstract <p></p>