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Residual stress distributions in 7075 aluminum alloy thick plates with different thicknesses and different quenching speeds were measured. A shape function of stress distribution was proposed based on the intal stress distribution characteristics of aluminum alloy. Using nonlinear regression technology, the function between stress value of key points on intal stress curve and surface stress of the plate was obtained. Based on the measured surface stress, stress value of key points and stress distribution shape, the intal stress distribution can be reconstructed. The experiments show that the model is of good engineering practicality.