Abstract: Aiming at the significant forming difficulties existing in Ti₂AlNb intermetallic compounds, the die forging forming process parameters were systematically optimized based on Deform-2D numerical simulation technology. Through systematic experimental verification and strict process implementation, the trial production of aero engine casing die forgings had been successfully achieved. The experimental results showed that the contour filling of die forging was full and complete. The overal properties analysis revealed that the range in mechanical properties between the high and low strain regions were controlled within 5%. The non-destructive clutter wave in ultrasonic testing reached ø1.2 mm-6 dB, demonstrating its excellent microstructure uniformity. This research achievement provided an effective process solution for the reliable manufacturing of key Ti₂AlNb die forgings for aero engines.