A thermal-mechanical coupled finite element model has been presented to predict residual and thermal stresses during different stages of stud welding. The finite study was carried out using three-dimensional models. To enhance the accuracy of the numerical solution material properties including physical, thermal and mechanical properties supposed to be temperature-dependent. After the temperature distributions as a result of welding were calculated, thermal and residual stress values obtained. Residual stresses are attributed to the elasto-plastic response of the object towards the transient thermal stresses generated by the welding. After all temperature values reach the room temperature, the residual stresses decrease to a small value.