Abstract: A reconstruction technology of finite element meshes based on reversal engineering was applied to solve mesh penetration and separation in the finite element simulation for the divergent extrusion. The 3D numerical simulation of the divergent extrusion process including the welding stage for complicated hollow sections was conducted. Based on the analysis of flowing behaviors, the flowing velocities of the alloy in portholes and near the welding planes were properly controlled through optimizing the expansion angle as well as porthole areas and positions. After the die structure optimization, defects such as warp, wrist, and the wavelike are eliminated, which improves the section-forming quality. Meanwhile, the temperature distribution in the cross section is uniform. Especially, the temperature of the C-shape notch with a larger thickness is lower than that of other regions in the cross section, which is beneficial for balancing the alloy flowing velocity.