Abstract The single lap joints were obtained with sheet metals of Al 6082-T651 alloy of thickness 2 mm and epoxy of two components. The strength of weld-bonded joints is found significantly higher than equivalent resistance spot welded joints. The role of elastic modulus of adhesive has been investigated computationally to find its affect on the pattern of stress distribution in the overlapped region. Prior to FE analysis experiments have been performed to find the weld characteristics to be utilized in the development of FE model.