In this study, a triple-layered AA 7075 build was developed by solid-state additive friction stir processing. The evolution of microstructure along the build was investigated using optical macroscopy and advanced characterisation techniques like electron backscattered diffraction and transmission electron microscopy. Distribution of hardness was measured along the build using the Vickers hardness tester. AFSP produced a recrystallised grain structure along the build due to dynamic recrystallisation. However, a non-homogeneous microstructure with a significant difference in grain size was observed along the build due to excess thermal cycles. A maximum hardness of 83.44 HV was obtained with the values dropping dramatically from the top to the bottom due to variations in the size of grains and the strengthening precipitates.
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