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Welding residual stresses and deformation in arc welded lap joints of thin steel plates were investigated by both numerical simulation and experimental measurement. A modified iterative substructure method was developed for the large deformation problem with locally strong nonlinearity, and the detailed distribution of welding residual stresses was obtained. It was demonstrated that the deformation mode of the top plate is different from that of the bottom plate. The out-of-plane deformation along the weld line has a convex shape and that along the transverse section has a concave shape. The strength of the base metal has a large influence on the residual stresses. The efficiency and accuracy of the proposed method have been validated by comparing numerical results with experimental results.

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