The effects of welding conditions on the residual stress and distortion behaviors of the full and partial-penetration weld joints with thin steel plates in the use of the electron beam welding process have been studied. Residual stresses and angular distortion were measured, and the experimental results have been verified with the aid of the thermal elastic-plastic analysis by the finite element method. The experimental results of residual stress and angular distortion have been clarified to be similar to the analysis results. The residual stresses (σT and σL) in the transverse and longitudinal directions with respect to the weld line have been confirmed to be shifted to the compression side in the vicinity of the weld toe when the beam power was higher and the beam diameter was smaller. The magnitude of residual stresses at the weld toe has been found to be related to the penetration depth. It has also been revealed that angular distortion tends to increase as the beam power becomes higher.
