What processing difficulties exist in manufacturing aviation aluminum alloy components?

High-strength aviation aluminum shows obvious work hardening during cutting and cold forming, accelerating tool wear and increasing processing costs. Thick aviation plates and large forgings generate huge internal residual stress after heat treatment, which easily triggers part deformation after machining and assembly. Welding of 7xxx ultra-high-strength aviation aluminum is restricted by hot cracking tendency, requiring special matching welding wires and strict temperature control. All forming processes need precise parameter calibration to guarantee dimensional tolerance for aviation safety-critical parts.