Aluminium Alloys for Aerospace Applications Industry Research Report 2025

Aluminium alloys play a critical role in aerospace applications due to their unique combination of lightweight, high strength, corrosion resistance, and manufacturability. These materials are typically aluminum-based and alloyed with elements such as copper, magnesium, zinc, silicon, and lithium to enhance specific properties. Aerospace-grade aluminium alloys are mainly classified into wrought alloys and casting alloys. Among the wrought types, the 2xxx series (aluminum-copper) and 7xxx series (aluminum-zinc-magnesium-copper) are commonly used for structural components due to their excellent strength and fatigue resistance. The 6xxx series, although less common in aerospace, offers moderate strength with good corrosion resistance and is sometimes used in internal structures. Advanced aluminium-lithium (Al-Li) alloys, developed in recent decades, offer reduced density and increased stiffness, making them ideal for modern fuselage panels, fuel tanks, and space-bound components. These alloys are selected not only for their mechanical properties but also for their behavior under cyclic loads, thermal variations, and environmental exposure, all of which are critical in aerospace environments.

To better understand their structural roles, it is helpful to examine representative alloy grades and their typical applications. Specific aluminium alloys serve different purposes based on their performance profile. For instance, 2024-T3 provides high fatigue resistance and is widely used in fuselage skins and wing surfaces, though it requires cladding due to poor corrosion resistance. 7075-T6 offers one of the highest strength levels among aluminium alloys and is used in wing spars, landing gears, and other high-load areas, though it can be prone to stress corrosion cracking. 7050-T7451 improves upon 7075 with better corrosion resistance and is often used in military aircraft bulkheads and structural parts. For applications requiring good weldability and corrosion resistance, such as internal cabin components and fluid transport systems, 6061-T6 is commonly used. In high-temperature and cryogenic applications like spacecraft fuel tanks, 2219 and Al-Li alloys such as 2195 and 8090 are preferred due to their high-temperature strength and low density. The selection of alloys depends heavily on structural requirements, environmental factors, manufacturing methods, and lifecycle performance.

As aerospace engineering advances, aluminium alloys continue to evolve alongside manufacturing technologies. Friction stir welding (FSW) is now widely applied for creating strong, defect-free joints in aluminium components, particularly in fuel tank and space applications. Additive manufacturing (AM), though still under development for high-strength aluminium, holds potential for complex, lightweight parts. Hybrid structural designs increasingly combine aluminium with carbon composites or titanium to optimize overall weight and performance. Meanwhile, sustainability trends are driving interest in recycling aerospace-grade aluminium for cost and environmental benefits. Despite the emergence of advanced composites and novel materials, aluminium remains foundational in aerospace structures due to its ideal combination of properties, established supply chains, and cost-effectiveness. Continued alloy development, especially in aluminium-lithium systems, ensures that aluminium alloys will remain indispensable in the next generation of aircraft and spacecraft.

Aluminium alloys have remained foundational in aerospace engineering due to their superior combination of low density, high specific strength, excellent fatigue and corrosion resistance, good machinability, and cost-effectiveness. Structurally, they dominate the airframe weight budget of modern aircraft, comprising approximately 40–70% of total structural mass. Aerospace-grade aluminium alloys are primarily divided into wrought and cast categories, with wrought alloys—including the 2xxx (Al-Cu) and 7xxx (Al-Zn-Mg-Cu) series—being the most widely used in structural components such as wing spars, fuselage skins, and bulkheads. The 6xxx series (Al-Mg-Si), though less dominant, is valued for its weldability and corrosion resistance in secondary structures. More recently, aluminium-lithium (Al-Li) alloys have gained traction due to their reduced density, increased stiffness, and enhanced damage tolerance, making them ideal for aerospace skins, stringers, floor beams, and cryogenic fuel tanks.

As aerospace components face increasingly complex operational loads and environments, alloy selection must consider not only strength but also lifecycle durability, weldability, residual stress, and anisotropy. The trade-offs between fatigue performance, corrosion resistance, and static strength are well illustrated by widely used grades such as 2024-T3, 7075-T6, and 7050-T7451, each optimized for specific structural scenarios. These considerations are central to material decisions in both commercial and defense aerospace platforms.

The development of ultra-high strength aluminium alloys—defined by yield strengths exceeding 500 MPa—has been a key advancement in replacing heavier or more expensive materials such as titanium. The 7xxx series remains the most prevalent in this class. Originally developed for aerospace and defense, these alloys now form the backbone of modern airframes, with a material share of up to 80% in some military aircraft. Alloys such as 7055, 7150, and 7475 offer high yield strength, but achieving a balance between strength and stress corrosion cracking remains a challenge. These issues have led to the development of new tempers (e.g., T73, T76, T77) and the use of trace alloying elements such as Cr, Mn, and Zr to improve corrosion resistance and fracture toughness. The evolution from T6 to T77 aging conditions reflects a trend toward higher toughness and corrosion resistance alongside strength retention.

From a processing perspective, thermal treatment plays a decisive role. Heat treatment sequences including solution heat treatment, aging (peak, overaging, retrogression and re-aging), and deformation-induced processes are used to refine precipitate morphology and control microstructure. Shape control, grain boundary stability, and fine-scale precipitate dispersion are critical for improving fatigue and corrosion properties. Advances in thermo-mechanical treatment (e.g., combination of hot deformation and high-temperature aging) and composite processes have significantly improved the damage tolerance and isotropy of thick-section aluminium parts. Friction stir welding (FSW) has become a standard joining method for fuselage and cryogenic tanks, offering high-strength, defect-free joints. Extrusion and rolled plate production have also undergone optimization to reduce interface defects, improve fatigue life, and support large, integrated structures.

Alongside traditional processing, new advanced manufacturing technologies are emerging to meet growing complexity and design flexibility. Additive manufacturing (AM), particularly in powder-bed fusion and directed energy deposition, is emerging as a viable method for high-performance aluminium parts. Although traditional aluminium alloys are difficult to print due to cracking and solidification issues, new AM-specific grades such as Scalmalloy (Al-Mg-Sc) and HOT Al are designed for stability at elevated temperatures and complex geometries. Powder metallurgy routes and microalloying with scandium and zirconium enhance grain refinement, precipitation control, and weldability, making them promising for structural applications. With ongoing advances in alloy design and process control, 3D printing is poised to complement conventional “subtractive” and “equal-material” manufacturing routes in aerospace.

Globally, the aluminium aerospace industry is led by companies like Arconic, Constellium, Novelis, Kaiser Aluminum, AMAG, and Aleris, which have developed multiple generations of commercial aerospace alloys. These companies supply forged and rolled products for aircraft components including wing skins, spars, fuselage frames, and floor beams. Western manufacturers have progressed through four generations of aluminium alloy development, with current efforts focused on achieving ultra-high strength (600–650 MPa) while maintaining damage tolerance and corrosion resistance. Advanced 7xxx series alloys like 7056, 7065, and 7255, and new 2xxx series such as 2524 and 2624, demonstrate optimized Zn, Cu, and microalloy element balances and impurity control, extending fatigue life and service safety margins.

In parallel, national programs across Asia and emerging economies are investing in aerospace-grade aluminium alloy development, building vertically integrated value chains from mining to alloy design and forming. While gaps remain in alloy IP, high-end equipment, and data-driven material certification, several regions are rapidly closing the distance through strategic partnerships, infrastructure upgrades, and AI-assisted metallurgy.

According to APO Research, the global aluminium alloys industry for aerospace applications reached a production value of USD 6.23 billion in 2025, with total output rising to 649,297 metric tons, reflecting a CAGR of 10.58% in value and 4.16% in volume between 2020 and 2024. The sector is entering a phase of accelerated expansion, with forecasted revenue expected to grow at 12.14% CAGR through 2031, reaching USD 12.38 billion by the end of the period. This growth trajectory is underpinned by resurgent demand in commercial aerospace, steady ramp-up in space launch systems, and the increasing integration of advanced alloys, particularly Aluminium–Lithium (Al–Li) grades.

From a typological standpoint, 7xxx series alloys (Al–Zn–Mg–Cu) remain the industry’s volume anchor, accounting for 254,524 tons in 2025 (39.2% of total output), driven by their continued dominance in wing structures and high-load airframe components. However, the fastest growing segment is Aluminium–Lithium alloys, projected to grow at 7.56% CAGR (2025–2031), with 2025 output reaching 102,654 tons and a market value of USD 1.18 billion. These alloys are increasingly adopted in both reusable launch systems and commercial fuselage panels due to their superior strength-to-weight ratio, cryogenic compatibility, and compatibility with friction stir welding.

Regionally, North America leads production with 281,210 tons in 2025 and will maintain dominance through 2031, supported by Kaiser Aluminum, Arconic, and Constellium’s Ravenswood and Trentwood facilities. Europe follows with 186,413 tons, concentrated around Constellium Issoire, AMAG Ranshofen, and Novelis Koblenz. China, while still a secondary contributor, has expanded to 124,211 tons in 2025, driven by vertically integrated programs under COMAC and AVIC, with production led by Southwest Aluminium, Nanshan, and Northeast Light Alloy. Asia Pacific, particularly Japan and China, is forecasted to outpace North America and Europe in production CAGR post-2025.

At the company level, Constellium, Novelis, Kaiser Aluminum, and Arconic collectively account for over 57% of global production value in 2025. Constellium, with its proprietary Airware® Al–Li series, reported USD 1.11 billion in aerospace revenue in 2025 at an average price of USD 13,274/t. Kaiser Aluminum, benefiting from capacity ramp-up at its Trentwood and Florence operations, grew output to 122,673 tons in 2025, generating USD 906.9 million in value, and continues to supply critical extrusions and forgings for Boeing, Lockheed Martin, and NASA. Arconic maintained its leadership in plate and Al–Li products, while AMAG Austria Metall AG showed the highest relative growth among European producers, reaching USD 464.7 million in aerospace alloy revenues in 2025, a 6-year CAGR of 16.2% from 2020.

From an application perspective, fuselage skins and fuselage structure continue to be the largest consumption segments, jointly accounting for over 54% of global alloy demand by weight in 2025. Their combined market value is projected at USD 3.64 billion, driven by the sustained build rate of Airbus A320neo, A350, and Boeing 737 MAX platforms. Notably, girder components and fuel tanks represent the most dynamic growth segments, supported by the adoption of next-generation Al–Li alloys in launch vehicles and space station modules. Fuel tank applications are expected to deliver a CAGR of 12.9% through 2031 in value terms.

Global price trends reflect moderate stabilization following the post-COVID surge in 2022–2023. The average industry price peaked at USD 10,066/t in 2022 and corrected to USD 9,589/t by 2025, balancing LME-linked volatility, energy inflation, and alloying element costs (notably lithium and scandium). Despite this, leading suppliers such as Novelis and Constellium sustain premiums above USD 11,000/t through differentiated quality, width capability, and qualification depth.

The supply base remains geographically concentrated and certification-intensive. Aerospace-qualified plate and extrusion facilities number fewer than 25 globally, with significant certification barriers (AMS, AS9100, NADCAP). This constraint has translated into limited short-term flexibility and persistent lead time volatility. Entry of Chinese and Russian producers into high-performance alloy segments is progressing but remains constrained by qualification gaps and limited adoption in Western aerospace programs.

Meanwhile, sustainability pressures are introducing a new dimension to procurement decisions. OEMs are now incorporating Scope 3 emissions into sourcing strategies, accelerating the shift toward low-carbon aluminium and closed-loop recycling practices. AMAG, Novelis, and Constellium have initiated deployment of hydropowered smelting and scrap reprocessing for certified aerospace inputs, though industry-wide recycled content in primary structures remains below 10% due to purity requirements.

In summary, the aluminium alloys for aerospace sector is entering a new growth cycle, shaped by structural recovery, technological transition, and supply-chain realignment. Demand will be increasingly segmented across commercial aviation, defense aerospace, and space systems, each with distinct alloy specifications, process expectations, and qualification paths. Suppliers capable of scaling certified capacity, expanding into Al–Li and high-strength Al–Cu systems, and aligning with emerging sustainability metrics will be best positioned to capture value in a supply-constrained, specification-driven market environment through 2031.

This report aims to provide a comprehensive presentation of the global market for Aluminium Alloys for Aerospace Applications, with quantitative and qualitative analysis, to help readers develop business/growth strategies, assess the market competitive situation, analyze their position in the current marketplace, and make informed business decisions regarding Aluminium Alloys for Aerospace Applications.

The Aluminium Alloys for Aerospace Applications market size, estimations, and forecasts are provided regarding sales volume (ktons) and revenue ($ million), considering 2024 as the base year, with history and forecast data for 2020 to 2031. This report segments the global Aluminium Alloys for Aerospace Applications market comprehensively. Regional market sizes concerning products by Type, by Application, and by players are also provided.

The report provides profiles of the competitive landscape, key competitors, and their respective market ranks to understand the market better. It also discusses technological trends and new product developments.

The report will help the Aluminium Alloys for Aerospace Applications manufacturers, new entrants, and industry chain-related companies in this market with information on the revenues, sales volume, and average price for the overall market and the sub-segments across the different segments, by company, by Type, by Application, and by regions.

Constellium

Novelis

Kaiser Aluminum

Arconic Corporation

Universal Alloy

AMAG Austria Metall AG

Kamensk-Uralsky Metallurgical Works

Southwest Aluminium

Shandong Nanshan Aluminium

Northeast Light Alloy

UACJ Corporation

7xxx Series (Al–Zn–Mg–Cu Alloys)

2xxx Series (Al–Cu Alloys)

6xxx Series (Al–Mg–Si Alloys)

5xxx Series (Al–Mg Alloys)

Aluminium–Lithium Alloys (Al–Li)

Fuselage Skins

Fuselage Structure

Girder

Rotor

Propeller

Fuel Tank

Other

North America

United States

Canada

Mexico

Europe

Germany

France

U.K.

Italy

Russia

Spain

Netherlands

Switzerland

Sweden

Poland

Asia-Pacific

China

Japan

South Korea

India

Australia

Taiwan

Southeast Asia

South America

Brazil

Argentina

Chile

Colombia

Middle East & Africa

Egypt

South Africa

Israel

Türkiye

GCC Countries

High-impact rendering factors and drivers have been studied in this report to aid the readers to understand the general development. Moreover, the report includes restraints and challenges that may act as stumbling blocks on the way of the players. This will assist the users to be attentive and make informed decisions related to business. Specialists have also laid their focus on the upcoming business prospects.

1. This report will help the readers to understand the competition within the industries and strategies for the competitive environment to enhance the potential profit. The report also focuses on the competitive landscape of the global Aluminium Alloys for Aerospace Applications market, and introduces in detail the market share, industry ranking, competitor ecosystem, market performance, new product development, operation situation, expansion, and acquisition. etc. of the main players, which helps the readers to identify the main competitors and deeply understand the competition pattern of the market.

2. This report will help stakeholders to understand the global industry status and trends of Aluminium Alloys for Aerospace Applications and provides them with information on key market drivers, restraints, challenges, and opportunities.

3. This report will help stakeholders to understand competitors better and gain more insights to strengthen their position in their businesses. The competitive landscape section includes the market share and rank (in volume and value), competitor ecosystem, new product development, expansion, and acquisition.

4. This report stays updated with novel technology integration, features, and the latest developments in the market

5. This report helps stakeholders to gain insights into which regions to target globally

6. This report helps stakeholders to gain insights into the end-user perception concerning the adoption of Aluminium Alloys for Aerospace Applications.

7. This report helps stakeholders to identify some of the key players in the market and understand their valuable contribution.

Chapter 1: Research objectives, research methods, data sources, data cross-validation;

Chapter 2: Introduces the report scope of the report, executive summary of different market segments (by region, product type, application, etc), including the market size of each market segment, future development potential, and so on. It offers a high-level view of the current state of the market and its likely evolution in the short to mid-term, and long term.

Chapter 3: Detailed analysis of Aluminium Alloys for Aerospace Applications manufacturers competitive landscape, price, production and value market share, latest development plan, merger, and acquisition information, etc.

Chapter 4: Provides profiles of key players, introducing the basic situation of the main companies in the market in detail, including product production/output, value, price, gross margin, product introduction, recent development, etc.

Chapter 5: Production/output, value of Aluminium Alloys for Aerospace Applications by region/country. It provides a quantitative analysis of the market size and development potential of each region in the next six years.

Chapter 6: Consumption of Aluminium Alloys for Aerospace Applications in regional level and country level. It provides a quantitative analysis of the market size and development potential of each region and its main countries and introduces the market development, future development prospects, market space, and production of each country in the world.

Chapter 7: Provides the analysis of various market segments by type, covering the market size and development potential of each market segment, to help readers find the blue ocean market in different market segments.

Chapter 8: Provides the analysis of various market segments by application, covering the market size and development potential of each market segment, to help readers find the blue ocean market in different downstream markets.

Chapter 9: Analysis of industrial chain, including the upstream and downstream of the industry.

Chapter 10: Introduces the market dynamics, latest developments of the market, the driving factors and restrictive factors of the market, the challenges and risks faced by manufacturers in the industry, and the analysis of relevant policies in the industry.

Chapter 11: The main points and conclusions of the report.