Semisolid rheological technology is an advanced casting process that can significantly refine the microstructure and improve the mechanical properties. However, the influences of fluid flow, solidification shrinkage and effective specific pressure on feeding distance during the semisolid forming process have not been investigated quantitatively. In this work, the one-dimensional (1D) model of limit feeding distance was developed for heterogeneous alloy melt with complex structures, and this alloy melt consisted of three phases including pure liquid phase, pure solid phase, and semisolid phase with the solid–liquid coexistence during pressurized rheoforming. The 1D model of limit feeding distance was derived from the semisolid rheological theory, and built on the basis of rheological feeding mechanism that the excess driving pressure caused sustained rheological feeding of alloy melts. Furthermore, the model covered three kinds of significant parameters including material property parameters, mold structure parameters and process parameters, so that it can be used to analyze the influence of various factors on the rheological feeding ability. In order to verify the theoretical model, the spiral samples of 6066 alloy were made at different velocities by squeeze casting. Moreover, the validity of theoretical model was verified through comparison of the numerical results and the length of samples without shrinkage porosity. The results showed that maximum relative deviation was only 6.8%. In addition, the effects of filling velocity, applied pressure, and the feeding channel initial diameter on the feeding distance were also discussed.

半固态流变技术是一种先进的铸造工艺，可以显着改善微观结构并改善机械性能。然而，尚未定量研究半固态成形过程中流体流动，凝固收缩和有效比压对进料距离的影响。在这项工作中，针对结构复杂的异质合金熔体建立了极限进料距离的一维（1D）模型，该合金熔体由三相组成，包括纯液相，纯固相和半固相，其中固相加压流变成形过程中液体共存。一维极限进料距离的模型是根据半固体流变理论得出的，并基于流变进料机理，即过高的驱动压力导致合金熔体持续流变进料。此外，该模型涵盖了三种重要的参数，包括材料性能参数，模具结构参数和工艺参数，因此可以用来分析各种因素对流变进料能力的影响。为了验证理论模型，通过挤压铸造以不同的速度制作了6066合金的螺旋试样。此外，通过对数值结果和无收缩孔隙率样品的长度进行比较，验证了理论模型的有效性。结果表明，最大相对偏差仅为6.8％。此外，填充速度，施加压力，