The influence of the specimen fabrication method on results of tension experiments on miniature ductile metal samples was investigated. 2024-T351 aluminum specimens were fabricated using traditional machining methods (milling) to two surface roughness specifications and using electrical discharge machining (EDM). The recast layer was left on the EDM specimens. The surface roughness of all samples was documented. The influence of edge-breaking the samples (rounding the sharp edges) was also investigated. Tests were conducted at two nominal strain rates: 1.0 s−1 using a servohydraulic load frame and 1000 s−1 using a tension split Hopkinson bar (SHB) apparatus. Results showed that the fabrication method influenced both the ultimate tensile stress and the elongation at failure. For milled specimens, the ultimate tensile stress and elongation decreased with increasing surface roughness. EDM specimens had slightly lower ultimate stresses but ductility in line with finely milled samples. Ultimate stresses of milled specimens with broken edges were lower than those with unbroken edges.
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