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In this study, the. geometrically non-linear thermal stress analysis of an adhesively bonded tubular single lap joint subjected to airflows having different temperature and velocity outside and inside its inner and outer tubes was carried out using the incremental finite element method. Since the thermal expansion coefficients of tubes and adhesive were different the thermal strains arising along the adhesive-tube interfaces resulted in high thermal stresses in the adhesive layer and tubes for different end conditions applied to the ends of its outer and inner tubes. The joint region was considerably deformed, and serious stress concentrations occurred around the adhesive free ends. This effect became more evident in cases the tube edges were fully restrained. The peak thermal adhesive and tube stresses occurred at the free ends, of the adhesive-tube interfaces. In addition, increasing the overlap length had an effect of reducing the peak adhesive and tube stresses, and an optimum overlap length/joint length ratio of 0.2 was determined. (C) 2002 Elsevier Science B.V. All rights reserved.