Date of Award


Thesis Date


Degree Type

Honors Thesis-Unrestricted

Degree Name



Mechanical Engineering

Degree Program

Mechanical Engineering


Michael Eller


The objective of the report is to investigate the feasibility and reliability of additive friction stir manufacturing of 7055 aluminum alloy. This is a technique in which multiple lap welds are performed to create a three-dimensional part out of relatively thin plate aluminum. To accomplish this, a four inch stack of 7055 aluminum alloy lap welds must be created. The solid weld nugget is then machined out of the center of the welded stack to create ASTM approved subsize tensile coupons. Rockwell hardness, yield strength, ultimate tensile strength, and percent elongation information is gathered from the tensile coupons to investigate the effectiveness of the additive friction stir manufacturing process. The data shows that the additive manufactured material experiences a significant reduction in strength and percent elongation while not showing any significant response to heat treatment. Suggestions are made regarding possible changes to the weld schedule that could improve the material properties of the additive manufactured aluminum.


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