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Welding Simulation of Cast Aluminium A356 X-T. Pham*, P. Gougeon and F-O. Gagnon Aluminium Technology Centre, National Research Council Canada Chicoutimi, Quebec, Canada Abstract Welding of cast aluminium hollow parts is a new promising technical trend for structural assemblies. However, big gap between components, weld porosity, large distortion and risk for hot cracking need to be dealt with. In this paper, the MIG welding of aluminium A356 cast square tubes is studied. The distortion of the welded tubes was predicted by numerical simulations. A good agreement between experimental and num