Method of producing a high-energy hydroformed structure from a 2XXX-series alloy

A method of producing an integrated monolithic aluminum structure, the method comprising the steps of:

• providing an aluminum alloy plate with a predetermined thickness of at least 31.75 mm, wherein the aluminum alloy plate is a 2xxx-series alloy provided in a T3-temper, and wherein the 2xxx-series alloy has a composition comprising, in wt. %:
• Cu 3.8% to 4.5%, Mn 0.3% to 0.8%, Mg 0.9% to 1.6%, Si up to 0.15%, Fe up to 0.20%, Cr up to 0.10%, Zn up to 0.25%, Ti up to 0.15%, Ag up to 0.10%, impurities and balance aluminum;
• optionally pre-machining of the aluminum alloy plate to an intermediate machined structure;
• high-energy hydroforming of the plate or optional intermediate machined structure against a forming surface of a rigid die having a contour in accordance with a desired curvature of the integrated monolithic aluminum structure, the high-energy forming causing the plate or the intermediate machined structure to conform to the contour of the forming surface to at least one of a uniaxial curvature and a biaxial curvature as a high-energy formed structure;
• machining or mechanical milling of the high-energy formed structure to a near-final or final machined integrated monolithic aluminum structure;
• and
• ageing of the final integrated monolithic aluminum structure to a desired temper.