In this study thermal stress generated in three ingot moulds(GC25) during the solidification process of aluminum were analyzed by the two-dimensional thermo-elasto-plastic theory. In temperature analysis, all of the three models are shown steep temperature rising each case in initial stage of cooling. In thermal stress analysis, all of three models took compressible stress on inside wall of the mould, and tensible along with on out side. Model 2 take place less compressible, tensible stress then model 1. But model 3. have similar as thermal stress as model 2. The analysis will made one possible to calculate an optimum mould shape whose thermal stress gradient becomes minimum.