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Aluminum Forgings for Aerospace Application

For the manufacturing of a modern aircraft, aluminum makes up 75%-80%!

The history of aluminum in the aerospace industry goes way back. In fact, aluminum was used in aviation before airplanes had even been invented. In the late 19th century, the Count Ferdinand Zeppelin used aluminum to make the frames of his famous Zeppelin airships. From them, due to the advantages of forging, lots of aluminum components are closed die forged. 

Benefits of Aluminum Forgings for Aerospace Application



With a number of beneficial properties, aluminum forging is an easy choice for manufacturing aircraft. Wood was originally used to build aircraft, but it is prone to rot and can splinter without proper maintenance. Likewise, steel forging is stronger than aluminum forging, but weighs significantly more. Steel forging is only used in aircraft when extremely high strength is needed, such as landing gears.

Some of the benefits of aluminum forgings include:
  • Light Weight — The use of aluminum alloys reduces the weight of an aircraft significantly. With a weight roughly a third lighter than steel, it allows an aircraft to either carry more weight, or become more fuel efficient.
  • High Strength — Closed die forging for aluminum components will greatly add its strength, allows it to replace heavier metals without the loss of strength associated with other metals, while benefitting from its lighter weight. Additionally, load-bearing structures can take advantage of aluminum’s strength to make aircraft production more reliable and cost-efficient.
  • Corrosion Resistance — For an aircraft and its passengers, corrosion can be extremely dangerous. Aluminum forgings for aerospace application are highly resistant to corrosion and chemical environments, making them especially valuable for aircrafts operating in highly corrosive maritime environments.

Common Grades of Aluminum Forgings for Aerospace Application


2024 – Typically used in aircraft skins, cowls, aircraft structures. Also used for repair and restoration.

3003 – This aluminum sheet is widely used for cowls and baffle plating.

5052 – Commonly used to make fuel tanks. 5052 has excellent corrosion resistance (particularly in marine applications).

6061 – Typically used for aircraft landing mats and many other non-aviation structural end-uses.

7075 – Commonly used to strengthen aircraft structures. 7075 is a high-strength alloy and is one of the most common grades used in the aviation industry (next to 2024).

Fly Drop Forge is a leading manufacturer of aluminum forgings in closed die forging process for aerospace application. End use applications include landing gear, engines, structural components, brakes and rotors components. Fly Forge has the experience and expertise in aluminum forgings that ensures the structural durability and high strength-to-weight ratio capabilities needed in a aluminum forged product for aerospace applications. We can supply all types of aluminum forgings , such as anodized treatment, ect. Contact us today to talk about your aluminum forgings needs and how we can get your project done quickly and to your specifications.

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