A novel technology of Spray-Conform (SC) directly combines spraying deposition with continuous extrusion into one process. The Al-Zn-Mg-Cu alloys were prepared by SC continuously. The microstructures of the fabricated Al-Zn-Mg-Cu alloys were studied through OM, SEM and STEM, the mechanical properties were summarized by tensile tests, and the electrical conductivity was measured to reflect corrosion resistance. The results revealed that the materials prepared by SC showed a fine and uniform microstructure. In particular, the grain size distributes in 1-2 μm before heat treatment. And the samples exhibited a better combination of mechanical properties and stress corrosion after RRA.
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