Research progress in semi-solid thixomolding technology of magnesium alloys

Because of their low density, magnesium alloys are strategically valuable for lightweight transportation equipment. Nevertheless, conventional casting processes encounter technical challenges, including shrinkage porosity, gas porosity, and oxidation. Thixomolding—an innovative forming process based on semi-solid processing principles-provides a viable approach to overcome these limitations. This work systematically elucidates the fundamental mechanisms of thixomolding, reveals the formation principles of non-dendritic microstructures and preparation methodologies for semi-solid slurries, and comprehensively analyzes the technology’s enhancement effects on the comprehensive properties of AZ-series and AM-series magnesium alloys. Currently, this technology has achieved industrial-scale implementation in consumer electronics and transportation equipment sectors. Supported by next-generation higher-tonnage forming systems, its applications are progressively expanding to large-scale structural component manufacturing, demonstrating exceptional development potential within the new energy vehicle industry. Among other crucial areas, future research should focus on defect control mechanisms for large-scale components, multi-physics coupled modeling of the forming process, and composition design of innovative thixomolded magnesium alloys.