200 YEARS OF ALUMINUM: FROM DISCOVERY TO INNOVATIVE MATERIALS AND STRUCTURES IN CONSTRUCTION AND ENGINEERING

The article, dedicated to the 200th anniversary of the discovery of aluminum, examines the formation of its engineering role – from a laboratory phenomenon to a strategic structural material that shapes innovative approaches in modern mechanical engineering, the aviation industry, and construction. In this context, modern technologies for manufacturing complex parts from aluminum alloys, which are of critical importance for precision manufacturing and next-generation structural systems, are considered. The authors focus on the key advantages of aluminum as a structural material – low density, high corrosion resistance, good machinability, and the ability to be recycled without losing its properties. Particular attention is paid to technologies such as pressure casting, friction welding, laser spraying, and additive manufacturing using aluminum powders, which enable the creation of large-sized, thin-walled components with high accuracy and minimal material loss. The paper provides examples of the use of aluminum alloys in the manufacture of body elements for electric vehicles and drones, as well as in advanced building structures. The importance of digital modeling and automated design is emphasized, as these tools allow for the optimization of part geometry, reduction of structural mass, and enhancement of energy efficiency. The influence of alloying elements (Mg, Si, Cu, Li) on the structure and mechanical properties of aluminum alloys is analyzed, along with methods for modifying the Al–Si eutectic structure to improve fluidity and reduce casting defects. The article presents a comparative analysis of traditional and modern methods for processing aluminum alloys, including gigacasting – a resource-efficient process for casting large parts using giant presses. The authors conclude that the integration of innovative technologies into production processes significantly enhances the competitiveness of aluminum components, reduces energy consumption, and promotes the development of a circular economy. For the construction industry, aluminum has become not only a means of implementing engineering solutions, but also a tool for architectural expressiveness, energy efficiency, and environmental safety – qualities that make it a highly promising material for the future.