Recent advances in high-quality and high-efficiency forming technologies for aluminum alloy components in transportation systems

Aluminum alloys are extensively employed in critical structural components of transportation equipment, encompassing the aerospace, automotive, and military vehicle sectors. The evolution toward high-performance lightweighting in next-generation transportation systems has generated an urgent demand for high-quality, high-efficiency forming and manufacturing technologies for aluminum alloy components. Typically, these components feature massive geometric dimensions and complex three-dimensional topologies, which, coupled with extreme performance requirements, present formidable manufacturing challenges. This paper systematically reviews the state-of-the-art and research progress in the plastic forming of aluminum alloy components for transportation equipment, comprehensively analyzing existing process routes and their inherent limitations. Particular emphasis is placed on elucidating the fundamental principles, technological breakthroughs, and engineering applications of emerging manufacturing paradigms, specifically cast-forge hybrid forming and pre-hardening forming technologies. Drawing upon representative case studies from the aviation, aerospace, and automotive sectors, the application efficacy and industrialization landscape of these novel plastic forming technologies are systematically evaluated. Finally, the future trajectories and critical challenges of high-quality, high-efficiency forming technologies are prospected, highlighting the pivotal roles of material-process-equipment synergistic innovation and AI-empowered intelligent manufacturing.