Abstract: Safra 66 aluminum alloy parts were directly formed by arc micro-casting and forging composite material increasing device. The microstructure and mechanical properties of Safra 66 aluminum alloy formed by arc free melt forming and arc micro-casting and forging were analyzed and tested. The fracture morphology of micro-cast and forging composite forming was studied by contrast. The results show that compared with that of arc free deposition forming, the microstructure of Safra 66 aluminum alloy is more uniform, the grain size is refined, the yield strength is increased by 31.1%, the tensile strength is increased by 11.3%, the elongation is increased by 20.0%, and the average hardness is increased by 15.5%.