REVIEW OF RECENT ADVANCES IN HIGH PERFORMANCE ALUMINIUM ALLOYS FOR AEROSPACE STRUCTURES
DOI:
https://doi.org/10.68302/std2026.vol2.181Keywords:
aerospace structures, aluminium alloys, mechanical properties, sustainable manufacturingAbstract
The increasing demand for lightweight, durable, and cost effective aerospace structures has renewed scientific and industrial interest in high performance aluminium alloys. This review aims to systematize and critically evaluate recent developments in aluminium alloys for aerospace structures and applications, with emphasis on the relation between alloy system, processing route, microstructure, functional performance, and service reliability. The study was conducted as a structured narrative review with integrative elements, based on recent peer-reviewed research and review articles published mainly from 2021 to 2026. The literature was classified according to alloy families, representative tempers, advanced processing routes, corrosion and fatigue mechanisms, joining technologies, and sustainability aspects. The synthesis indicates that 2xxx, 7xxx, and aluminium lithium alloys remain the most important alloy groups for aeronautical and space structures, while additively manufactured aluminium alloys are becoming increasingly relevant for lightweight and geometrically complex components. The results also show that alloy performance is controlled by coupled effects of alloying, heat treatment, thermomechanical processing, precipitation state, grain structure, defects, surface condition, and environmental exposure. Corrosion fatigue, stress corrosion cracking, additive manufacturing defects, joining related degradation, and sustainable recycling remain key challenges. The literature suggests that aluminium alloys retain a significant aerospace role because they combine low density, mechanical efficiency, manufacturability, repairability, recyclability, and economic viability. Future progress requires integrated alloy design, defect tolerant processing, environmentally safer surface protection, reliable life prediction, and stronger links between materials development and life cycle sustainability.
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