Abstract：Based on the butt joint of thin-walled aluminum alloy pipe, according to the practical situation, three-dimensional thermal, metallurgical and mechanical finite element model was established. The temperature field during welding process, axial and hoop residual stresses of circumferential welds incorporating metallurgical phase transformation were simulated by using SYSWELD software. The model was accurately predict the welding residual stresses and the results coincided with experiment. In addition, the effects of pipe diameter on residual stresses were investigated. The results showed that affected metallurgical phase transformation on the maximum axial tensile stress and maximum hoop tensile stress and compressive stress, and models with metallurgical phase transformation can simulate axial and hoop stresses more accurately; considering phase transformation, the residual stresses increased with increasing the radius, and residual stresses with different radii have a similar trend.
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