Based on the commercial software ABAQUS, a thermo-elastic-plastic finite element method (T-E-P FEM) was developed in consideration of material nonlinearity, geometrical nonlinearity and moving heat source to simulate the thermo-mechanical behavior during welding process. The welding temperature fields, residual stress distribution and deformation in a thin-plate bead-on joint performed by TIG welding process and those in a butt joint with V-groove welded by MIG welding process were simulated. Meanwhile, the transverse shrinkages and out-of-plane deformations in thin-plate welded joints were measured by experiments. The transverse shrinkages and the out-of-deformations simulated by the T-E-P FEM are in good agreement with the measured data, and the effectiveness of the developed computational approach was verified by experiment. In addition, the formation mechanisms of out-of-plane deformation in thin-plate Al alloy joints were clarified based on the numerical and experimental results.

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