Semisolid metal (SSM) forming offers many manufacturing and economic advantages over conventional die casting or forging processes in a number of ferrous and non-ferrous alloy systems, that include Al alloys. SSM forming requires a fine grained feedstock with a special non-dendritic, spheroidal primary solid microstructure produced by shearing or stirring the alloy in a semisolid state. In the case of Al-rich alloys the primary solid phase is {alpha}-Al. Upon reheating the feedstock is rendered a slurry of spheroidal solid particles suspended in a liquid matrix with proper rheological properties for subsequent forming operations. The high cost of primary Al and Al alloys makes the economical production of feedstock with acceptable microstructure absolutely critical to the viability of SSM forming as an alternative process, despite its other attractive aspects. Current commercially produced feedstock for Al alloy SSM is almost wholly confined to two processing routes: a solid state processing route involving thermomechanical treatment and recrystallization, that is confined to small diameter feedstock and a liquid processing route that employs electromagnetically (MHD) stirred direct chill (DC) continuously cast semisolid. It is not apparent that either of the present commercial processing routes has been fully optimized in terms of defining the minimum level of spheroidization of primary solid required for the production of acceptable feedstock rheology for forming. This type of optimization via mechanical stirring would thus result in significant processing economies. Therefore, the feasibility of a liquid processing route for production of fine grained small diameter feedstock, that utilizes mechanical stirring of the semisolid and slurry formation decoupled from slurry solidification, was investigated for this Phase 1 research project.