• Semi-solid (SS) thixoforming is a forming process at temperatures located inside the fusion interval.
• Combines the advantages of casting and forging.
• Introduction of an internal parameter to describe microstructure evolution.
• Thermo-elasto-viscoplastic material model.

Globular structure, as well as semi-solid state, is essential to obtain this behaviour.

• Extrusion of cylindrical steel slug through a conical die.
• ALE mesh management is critical to avoid remeshing.