<p>Welding, a critical technique for joining metals across various industries, introduces residual stresses that significantly affect the mechanical properties and structural performance of welded components. This study investigates the impact of welding-induced residual stresses on the mechanical characteristics and structural behavior of gusset plates used in steel bracing. Finite element analysis (FEA) and sequential (indirect) coupled analysis were employed, with results validated against experimental data. 72 numerical models of gusset plate connections, varying in connection length and plate thickness, were analyzed with and without welding effects. Compared to non-welded conditions, welded gusset plates exhibited an average reduction in ultimate strength and stiffness of 12% and 17%, respectively, highlighting the importance of considering residual stresses in structural design.</p>