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With the increasing requirements of shield tunnel construction, the demand for the development and application of high-performance lining segments continues to rise. During the manufacture and forming process of high-performance composite segments, large-scale shear key welding is an important factor affecting the mechanical performance of segments. This paper aims to study the effect of shear key welding on the mechanical properties of composite segments. In this study, the algorithm transformation of the welding heat source model was first conducted. Then, a comprehensive analysis of the shear key was presented using the finite-element method, and a welding experiment was conducted to verify the reliability of the adopted numerical model. It was found that the temperature of the welding point changes with the movement of the heat source in the shear key welding, in which the maximum temperature peak can reach 2,236 K. The welding residual stress was mainly concentrated in the range of about 30 mm from the welding point, and then the value decreased gradually. In the welding of multiple shear keys, the residual stress at the central axis of adjacent shear keys will be superimposed, and the mutual influence of adjacent shear keys during welding should be avoided. Through a key-panel welding experiment, the numerical simulation results of the shear key-panel model were verified. The panel deformation at the edge position was also affected by the boundary conditions. [ABSTRACT FROM AUTHOR]