7075 aluminum alloy was prepared by spray deposition and continuous extrusion to eliminate the defects such as element segregation

coarse structure and uneven distribution of second phase and shrintage porosities and holes

and the microstructure and element distribution were compared with those of the as-cast alloy. The results indicate that the spray deposited and continuous extruded 7075 aluminum alloy has low content of impurity elements

fine microstructure and uniform distribution of alloying elements. The OM microstructure reveals that the average grain size of the deposited blank is significantly reduced compared with that of the casting alloy

presenting equiaxed crystal. After continuous extrusion

the matrix density is increased

and the second phase is refined and distributed uniformly along the extrusion direction. The TEM microstructure observes that the billets undergo dynamic recrystallization during continuous extrusion

and the average recrystallized grain size is 3～5 μm. The yield strength and elongation of alloy after retrogression and re-aging treatment reach 493 MPa and 12.6%

which exceed 9.6% and 26% of the aviation standard AMS 4050 H limit

respectively. The EDS results demonstrate that the segregation of the main alloy elements prepared is well inhibited

and the impurity elements of oxygen and carbon are more evenly distributed

which is conducive to improving comprehensive properties of the alloy.