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Distortion frequently occurs during machining of age hardening aluminum alloys due to residual stresses introduced during the quenching step in the heat treatment process. This report quantifies, compares, and discusses the effectiveness of several methods for minimizing residual stresses and machining distortion in aluminum alloys 7075 and 6061. 4 ACKNOWLEDGMENTSMany colleagues participated in portions of this study. The authors appreciate the efforts of Gary Gallegos and Don Green, who conducted the heat treatment and quenching experiments; Jack Stephens, Roger Castillo, and Joe Nekoranec, who machined the test samples and measured subsequent distortions; and Tom Crenshaw and John Laing, who conducted the mechanical tests. We also appreciate the comments and helpful reviews of Jim VanDenAvyle, Don Susan, and Curtis Gibson.5

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