Effects of hot extrusion texture on anisotropy in microstructure and mechanical properties of spray formed Al–Zn–Mg–Cu 7055 aluminum alloy

The Al–Zn–Mg–Cu 7055 aluminum alloy was meticulously fabricated through spray forming (SF) technology, followed by hot extrusion and T76 treatment. This comprehensive process allowed for a thorough investigation of its microstructural characteristics, mechanical properties, and fatigue behavior. Post-treatment analysis revealed that the SF-7055 aluminum alloy exhibited no notable segregation or porosity defects, ensuring its exceptional quality and reliability. The microstructural analysis revealed a uniform distribution of refined grains and dispersed precipitates, contributing to the material's strength. Mechanical testing demonstrated that the hot extruded SF-7055 aluminum alloy exhibits superior tensile strength and elongation, with significant anisotropy in mechanical properties favoring the extrusion direction (ED) over the transverse direction (TD). Fatigue testing under varying cyclic stresses revealed an extended fatigue life in the ED-oriented specimens, attributed to the texture-induced resistance to crack initiation and propagation. The study underscores the effectiveness of SF and hot extrusion in enhancing the SF-7055 aluminum alloy's performance, making it a viable candidate for critical aerospace applications. The findings provide valuable insights into the relationship between processing, microstructure, and properties, offering a pathway to the design and fabrication of high-performance aluminum alloys.