Abstract <p>Magnesium alloys have emerged as promising lightweight materials for automotive, aerospace, and electronic applications, but their limited mechanical properties restrict broader industrial use. Despite these limitations, semisolid processing yields competitive tensile strength and a significant density advantage over aluminum, positioning magnesium as a strategic alternative for weight-critical applications. Semisolid processing has gained attention as an effective method for refining microstructures and enhancing the mechanical behavior of Mg alloys. The selection of a semisolid processing method for magnesium alloys hinges on crucial criteria for the slurry's preparation techniques, such as shear rate, solid fraction, and sensitivity to inclusions. A comprehensive evaluation of these factors is essential to achieve optimal component quality. Among the available techniques, electromagnetic stirring (EMS) stands out due to its non-contact operation, reduced contamination risk, and effectiveness in promoting globular grain formation. This review presents a comprehensive analysis of EMS techniques applied to semisolid processing of Mg alloys, including low- and high-frequency stirring, annular electromagnetic stirring, and pulsed magnetic field methods. The physical principles governing EMS (especially the role of Lorentz force in grain refinement) are discussed in detail, along with the impact of process parameters on microstructure and mechanical performance. Furthermore, numerical simulations and modeling strategies are explored to optimize EMS conditions. The review concludes by identifying current challenges and opportunities for future research to improve the scalability, precision, and industrial viability of EMS-based semisolid processing of magnesium alloys.</p> Graphical Abstract <p></p>

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Advances in Electromagnetic Stirring (EMS) and Slurry Preparation Technologies of Magnesium Alloys: A Comprehensive Review

  • A. Habibi Eftekhar,
  • S. Mohsen Sadrossadat,
  • M. Reihanian,
  • Kh. Gheisari

摘要

Abstract

Magnesium alloys have emerged as promising lightweight materials for automotive, aerospace, and electronic applications, but their limited mechanical properties restrict broader industrial use. Despite these limitations, semisolid processing yields competitive tensile strength and a significant density advantage over aluminum, positioning magnesium as a strategic alternative for weight-critical applications. Semisolid processing has gained attention as an effective method for refining microstructures and enhancing the mechanical behavior of Mg alloys. The selection of a semisolid processing method for magnesium alloys hinges on crucial criteria for the slurry's preparation techniques, such as shear rate, solid fraction, and sensitivity to inclusions. A comprehensive evaluation of these factors is essential to achieve optimal component quality. Among the available techniques, electromagnetic stirring (EMS) stands out due to its non-contact operation, reduced contamination risk, and effectiveness in promoting globular grain formation. This review presents a comprehensive analysis of EMS techniques applied to semisolid processing of Mg alloys, including low- and high-frequency stirring, annular electromagnetic stirring, and pulsed magnetic field methods. The physical principles governing EMS (especially the role of Lorentz force in grain refinement) are discussed in detail, along with the impact of process parameters on microstructure and mechanical performance. Furthermore, numerical simulations and modeling strategies are explored to optimize EMS conditions. The review concludes by identifying current challenges and opportunities for future research to improve the scalability, precision, and industrial viability of EMS-based semisolid processing of magnesium alloys.

Graphical Abstract