Abstract: Welding production of the 4 mm thick 5A06 aluminum alloy variable diameter thin wall shell assembly was carried out by using manual pulsed TIG welding.The welding material, groove preparation, prewelding cleaning and welding fixture were determined. The manual pulsed TIG welding test of 5A06 aluminum alloy plate was carried out firstly, and the welding process parameters of the shell assembly were determined. The welding production of the shell assembly shows that the welding procedures are feasible, and the quality of the shell assembly meets the welding requirement.