Abstract: The structural static calculation and finite element simulation of the 6061 aluminum alloy truss structure were carried out. Then the cold arc welding process was used for joint forming, and the truss structure was crushed and the microstructure of the joint was observed by metallographic microscope. The results show that the critical load capacity of the failure after simplified calculation and simulation is 33.55 kN, which is slightly smaller than the actual measured value of 33.8 kN in the actual crush test, it is exactly the same deformation position simulated by abaqus and the actual deformation position of the crush test.. The welded joints after the crushing test were well formed on the macroscopic surface. The microscopic morphology showed that the interfacial growth process of the welds at the joints remained the original shape after a certain period of static crushing process, and no intergranular and transgranular cracks/fracture were found on the grain boundaries.