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Two finite element(FE) models were built up for analysis of stress field in the lining of aluminum electrolysis cells. Distribution of sodium concentration in cathode carbon blocks was calculated by one FE model of a cathode block. Thermal stress field was calculated by the other slice model of the cell at the end of the heating-up. Then stresses coupling thermal and sodium expansion were considered after 30 d start-up. The results indicate that sodium penetrates to the bottom of the cathode block after 30 d start-up. The semi-graphitic carbon block has the largest stress at the thermal stage. After 30 d start-up the anthracitic carbon has the greatest sodium expansion stress and the graphitized carbon has the lowest sodium expansion stress. Sodium penetration can cause larger deformation and stress in the cathode carbon block than thermal expansion.