This study aims to bridge the critical knowledge gap in understanding the dynamic microstructural evolution during high-solid-fraction semi-solid rheo-die casting process, including slurry preparation (0.1–0.3 K/s) and rheo-die casting (10–150 K/s). A novel phase-field model coupling continuous cooling with explicit nucleation was developed, enabling the dynamic simulation of continuous solidification microstructure evolution, considering two-stage cooling rate transition characteristics. Integrated the Swirled Enthalpy Equilibration Device (SEED) slurry preparation and graded-cooling mold experiments established variable cooling rate and solid fraction conditions for quantitative analysis of α-Al morphological evolution during rheo-die casting solidification. Through experimental and simulation investigations of the Al-7Si alloy, it is concluded that during Stage I slurry preparation, the primary α₁-Al phase coarsened due to Ostwald ripening. In Stage II rheo-die casting, primary α₁-Al undergoes continued growth under a moderate cooling rate (15 K/s). Meanwhile, secondary α₂-Al formation exhibits a cooling-rate and solid fraction dependence: a high cooling rate (150 K/s) promotes explosive nucleation with the volume fraction decreasing from 4.78% to 0.33% as the solid fraction rises, whereas a mid-cooling rate (15 K/s) substantially suppresses its formation. Mechanistically, a high cooling rate promotes solute trapping, which intensifies constitutional undercooling, thereby elevating both the nucleation and growth driving forces to facilitate the formation of secondary α₂-Al, whereas higher solid fractions restrict secondary phase formation by narrowing the solidification windows from 22 °C to 7 °C.

The synergistic effects of solute concentration and cooling rate on the evolution of secondary α₂-Al during high-solid-fraction rheo-diecasting of Al-xSi (x = 1, 4, 7 wt.%) alloys was studied. Combined gradient-cooling experiments (100 vs. 10 K/s) and phase-field simulations show that the population and morphology of secondary α₂-Al are co-governed by initial Si content and cooling rate. Higher cooling rates promote finer, more uniform secondary α₂-Al in Al-1Si and Al-4Si, while lower cooling rates cause coarsening and coalescence. In addition, the formation of α₂-Al is severely suppressed in Al-7Si. Crucially, a lower initial solute concentration significantly amplifies cooling rate-induced solute enrichment, quantitatively evidenced by the final liquid concentration difference (Al-1Si: 0.83 wt.% > Al-4Si: 0.29 wt.% > Al-7Si: 0.13 wt.%). This enrichment governs the dynamic competition between constitutional and thermal undercooling, contributing a substantially greater driving force for early-stage nucleation in Al-1Si compared to Al-7Si. As solidification progresses in all three systems, the enrichment of the residual liquid narrows the solidification interval, thereby progressively elevating the role of thermal undercooling.