Abstract: Aiming at the problematic issues occured in stud welding in large diameter component, such as gas pore, hot crack and incomplete fusion and poor joint, a welding technology was proposed using TIG-Arc hybrid heating sourceand conducted on Φ16 mm aluminum stud welding. Before the welding of aluminum stud, immersion plating of Zn-Ni layer was applied on the aluminum stud. The whole welding process was protected with inert gas. The shear strength of joint can reached 128 MPa and the strength coefficient of the joint is above 70%. The optimum welding parameters are, preheating temperature of 200℃, welding time of 1000 ms, welding current of 650 A. The experimental results also show that the pretreatment of aluminum by TIG and Zn-Ni plating of can effectively improve the mechanical properties and the microstructure of the joint.