Aluminum alloy hot stamping technology has quickly become a research hotspot for many scholars due to its ability to solve key challenges such as poor formability, large rebound, and low dimensional accuracy of aluminum alloy sheets at room temperature. This work systematically reviews the progress of Hot-Forming-Quenching (HFQ^®) technology and its optimization processes. The effects of key forming parameters are summarized, including temperature, forming rate, friction, and crimping force on the forming properties of aluminum alloys. Additionally, an ontological model of thermal deformation behavior and damage evolution during hot forming is analyzed. A multifactorial strength prediction model, integrating grain size and reinforcement mechanisms, is highlighted for its ability to accurately predict post-forming yield strength. To address the limitations of HFQ^®, optimization methods for solid solution and aging heat-treatment stages are categorized and evaluated, along with their advantages and disadvantages. Furthermore, the latest advancements in two innovative hot stamping processes (Low-Temperature Hot Form and Quench (LT-HFQ^®) and pre-hardened hot forming (PHF)) are reviewed. LT-HFQ^® improves formability by pre-cooling the sheet while maintaining solution treatment, while PHF utilizes pre-hardened aluminum alloys, enabling brief heating, forming, and quenching to significantly reduce cycle time while ensuring component strength. Finally, by summarizing current technological progress and challenges, future directions for aluminum alloy hot stamping are outlined, including advancements in forming processes, material modeling, and optimization through multidisciplinary collaboration and artificial intelligence to drive further innovation.

High-strength steel (HSS) plates are widely used due to their superior performance. However, residual stresses generated during welding can exacerbate the initiation of fatigue cracks, and the accurate prediction of residual stresses is crucial. Therefore, thermo-mechanical behavior analysis of the EH40 joints was completed based on the proposed new heat source model. The thermo-elastoplastic finite element analysis was determined via thermo-mechanical coupling with fully parametric programming. The influence of laser welding power and joint thickness on peak temperature and gradient was clarified. Meanwhile, it was found that when the laser welding power increased from 9 kW to 22.5 kW and the joint thickness increased from 6 mm to 15 mm, the distribution trend of longitudinal residual stress in the weld zone was gradually altered from a “U” shape to a “W” shape, while the transverse stress was transformed from a “U” shape to an “M” shape. It was determined that the amplitude of longitudinal and transverse stress changed along the thickness direction of nodes and was directly proportional to the peak temperature. The above results imply that the peak temperature, maximum temperature gradient longitudinal, and transverse residual stress distribution in the weld zone and its vicinity were remarkably affected by laser welding power and joint thickness.