A Review on Ultra-High-Strength Aluminum Alloys for Aerospace Applications: Forming, Microstructure, and Mechanical Properties

The increasing demand for lightweight aerospace structures has driven the continuous development of ultra-high-strength aluminum alloys (UHSAAs). Owing to their low density and high specific strength, UHSAAs remain the primary materials for next-generation aerospace structural components. Over the past decades, their tensile strength has increased from the 500 MPa level to beyond 700 MPa, accompanied by a shift in research focus from strength maximization to the synergistic optimization of strength, ductility, and damage tolerance. This work concentrates on 7xxx series and Al-Li alloys, systematically reviewing recent research advances and key challenges in alloy design and forming. Particular emphasis is placed on new strategies for strength-ductility synergy and the associated microstructural strengthening and toughening mechanisms. Finally, future development directions are discussed to provide guidance for the design and engineering application of high-performance aerospace aluminum alloys.