Four　different　shapes　of　aluminum　foil　were　proposed　to　investigate　the　effects　of　foil　shape　on　current　density,　temperature　distribution,　weld　area　and　deposition　energy　by　combining　numerical　simulation　and　process　experiment.　The　experimental　results　indicate　that　for　conventional　transition　type　and　V-shaped　transition　type　aluminum　foils　with　corner　structures,　there　exists　the　characteristic　of　a　small　peak　temperature　zone　area　and　premature　explosion　at　sharp　points;　for　arc　transition　type　aluminum　foil　with　symmetrical　structures,　the　area　of　temperature　changes　smoothly　but　there　is　energy　loss　during　the　welding　process;　among　the　four　different　shapes　of　aluminum　foils,　the　edge-bridge　transition　type　aluminum　foil　has　the　highest　peak　voltage,　longest　discharge　time,　the　most　deposition　energy　and　the　highest　energy　utilization　efficiency,　and　the　largest　weld　area,　resulting　in　the　best　joint　mechanical　performance,　with　the　maximum　tensile-shear　force　of　7726　N,　which　is　close　to　the　base　material.　©　2025　Beijing　Res.　Inst.　of　Mechanical　and　Elec.　Technology.　All　rights　reserved.