Method of producing a high-energy hydroformed structure from a 7xxx-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 38.1 mm, wherein the aluminum alloy plate is a 7xxx-series alloy provided in an F-temper or an O-temper;
• optionally pre-machining of the aluminum alloy plate to an intermediate machined structure;
• high-energy hydroforming of the plate or optional intermediate machined structure into a high-energy hydroformed 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 hydroforming 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;
• solution heat-treating and cooling of the high-energy hydroformed structure;
• machining of the solution heat-treated high-energy formed structure to a final machined integrated monolithic aluminum structure;
• and
• ageing of the final integrated monolithic aluminum structure to a desired temper,
• wherein said solution heat-treated structure is stress-relieved by compressive forming in a next high-energy hydroforming step.