• The work explores the potential of one of the most demanding alloy (Al-Li) in the aerospace sector. • Milling process has the ability to improve the functional performance of the alloy to a great extent. • Great surface integrity characteristics in terms of roughness, hardness and residual stress. • Limited microstructural damage can be expected from milling process. • Very limited prior studies on the machining induced behaviour of this alloy. This work presents the milling induced surface integrity investigation of Al-Li alloy. The effect of milling on the surface roughness, microhardness, microstructure, and residual stress is studied. Uncoated carbide inserts are used for milling due their superior hardness and greater life, when machining softer materials such as aluminium and its alloys. Results show that the minimum surface roughness (Ra = 0.043 µm) and maximum microhardness (216 HV) are achievable from the milling process, when compared with the roughness (Ra = 0.528 µm) and microhardness (180 HV) of the as-received material. Results indicate limited harm to alloy microstructure from the milling process and the presence of compressive residual stress induced from milling. The work finds scope for aerospace applications.