Severe plastic deformation (SPD) to large strains can lead to a considerable refinement of the grain size of a metal, leading to very high strength when ultra-fine grains are produced. The ultrafine gain material, produced by SPD processing, also exhibits superplastic like behavior, leading to the potential for high hot formability. In this study, fine-grained aluminum alloy 6061 with a square cross-section of 50 mm (2 inches) was produced by severe plastic deformation. The microstructure was characterized using optical and transmission electron microscopy. Hot forging studies were conducted in an industrial environment to demonstrate enhanced hot forgeability for SPD processed material. The SPD processed material and conventional forging stock material were used as forging stock to produce several forgings. Results indicate that the SPD processed material offers better die fill at lower temperatures and with less stock material than the conventional forging stock. The forging studies also included the measurement of fuel consumption for hot forging at various temperatures and for different thickness materials as a function of time. The implications of the decreased material usage and the lower temperatures on energy and cost savings will be discussed.