The objective of this study is to analyse residual stress of the Al/steel butt joint using the laser welding–brazing. The welding parameters were a laser power of 1200 W, a welding speed of 600 mm min−1, thickness of 150×150×2 mm and 150×150×1 mm, respectively. The residual stress was measured by the hole-drilling methods. Then, a finite-element model of the welding process was established, and it was verified by experiments. The results show that the calculated results are in conformity with the experimental results. The longitudinal residual stress on the galvanised steel (329 MPa) is larger than that on the aluminium alloy (293 MPa). At the location of the fixture, the longitudinal residual stress is substantially zero.
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