Abstract: In order to improve the prediction accuracy of welding deformation and residual stress of hollow thin-walled aluminum alloy structures, based on the inherent strain method, the welding equivalent load was solved by using the welding thermal parameters, moreover, from the perspective of deformation and residual stress, the welding deformation and welding residual stress were analyzed by finite element simulation, and then the deformation was verified by welding experiment. The results show that the covering plate on the structural member is saddle shaped, and the maximum deformation caused by welding is distributed on the left and right sides of the upper cover plate, the maximum simulation values on the left and right sides are 0.299 mm and 0.274 mm respectively, and the maximum experiment values on the left and right sides are 0.37 mm and 0.34 mm respectively, and the experiment deformation value is slightly larger than the simulation deformation value, and the prediction error rates of deformation on the left and right sides are 19.1% and 19.4% respectively. The research results can provide a reference for the prediction of welding deformation and residual stress of similar hollow thin-walled aluminum alloy structural parts.