• Cryogenic forging with pre-deformation (PCF) significantly refines surface coarse grains, producing a finer and more uniform microstructure than traditional thermal forging.
• The PCF process accumulates higher stored energy via increased dislocation density, promoting static recrystallization (SRX) during subsequent heat treatment.
• OM, EBSD, and TEM analyses confirm that PCF enhances strain accumulation, dislocation density, and grain refinement in 7050 aluminum forgings.
• This method improves microstructural uniformity and mechanical performance, offering a promising solution for aerospace and aluminum forging industries.