Microstructure evolution and mechanical properties of Al–Zn–Mg–Cu alloy reprocessed by spray-forming and heat treated at peak aged condition

•We evaluated the influence of the spray forming in the microstructure.•Refined microstructure with low level of segregation was obtained.•It were provided good mechanical properties at the end stage of the processing.•The artificial aging provided a fine nanosized distribution of η′ precipitates.•Spray forming showed to be a promissory route to reprocess 7000 Al alloys. Machining chips of the alloy AA7050 were reprocessed by spray forming followed by hot-extrusion and heat treatment. The spray-formed deposit presented a microstructure with hardening η′ precipitates within the matrix and equilibrium η precipitates at the grain boundaries, refined grains and low segregation of the main elements Zn, Cu and Mg. The final microstructure at peak aged condition is mainly composed by Guinier–Preston (GP) zones, η′ metastable, η equilibrium , Al3Zr dispersoids and the coarse Al7Cu2Fe intermetallic. A well-defined precipitation free zone along grain boundaries was not observed. Good mechanical properties were achieved.