Friction stir extrusion (FSE) is a process based on the heat generated by friction between die and materials in which a sample is produced through consolidation and extrusion of precursor materials such as metal chips. In this paper, the wire samples produced by friction extrusion of aluminum alloy AA7022 chips are investigated. The samples were extruded at different rotational speeds and extrusion forces, and impacts of these two parameters were studied. At first, structural properties of samples were studied using optical microscopy and scanning electron microscopy (SEM). The result showed that the samples produced at higher rotational speeds and lower forces had a far better surface quality and lower surface crack were seen on them. On the other hand, the temperature of process and grain size were increased with rise of rotational speed. The SEM micrographs showed that by changing rotational speed and extrusion force, the amount of adhesion and sintering between aluminum particles change and by optimizing these parameters can decrease wire’s internal defects and pits. In the following, to study mechanical properties, micro hardness and compression tests were used. The values of hardness and yield stress of samples were decreased with increasing rotational speed and increasing the extrusion force to a certain extent caused increase in yield stress of material.