以铝合金薄壁管的对接接头为研究对象,根据实际情况建立了其热-冶金-力学耦合的三维有限元模型,运用SYSWELD软件在考虑相变情况下对其焊接过程温度场与轴向和环向残余应力分布进行数值计算与分析,与实验结果进行对比验证了该模型的准确性.此外,还分析了铝合金管半径变化对残余应力分布的影响规律.结果表明:相变对轴向最大拉应力与环向最大拉应力和压应力都有明显的影响,且考虑相变能更准确地模拟轴向和环向残余应力；在考虑相变情况下,焊接残余应力随半径的增大而增加；并且在不同的半径条件下,距焊缝中心不同距离上的应力分布有着一致的变化趋势.
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