An aluminum extrusion process is mainly used to fabricate long tubes, beams and rods for various applications.However, this process has a high production cost due to the need for investment of high-pressure machinery.The objective of this work is to develop a new semi-solid extrusion process using semi-solid slurry at low solid fractions.A laboratory extrusion system was used to fabricate aluminum rods with the diameter of 12 mm.The semi-solid metal process used in this study was the gas induced semi-solid (GISS) technique.To study the feasibility of the GISS extrusion process, the effects of extrusion parameters such as plunger speed and solid fraction on the extrudability, microstructure, and mechanical properties of extruded samples were investigated.The results show that the plunger speed and solid fraction of the semi-solid metal need to be carefully controlled to produce complete extruded parts. An aluminum extrusion process is mainly used to fabricate long tubes, beams and rods for various applications. However, this process has a high production cost due to the need for investment of high-pressure machinery. Objectives of this work is to develop a new semi-solid extrusion process using semi-solid slurry at low solid fractions. A laboratory extrusion system was used to fabricate aluminum rods with the diameter of 12 mm. The semi-solid metal process used in this study was the gas induced semi-solid GISS) technique. To study the feasibility of the GISS extrusion process, the effects of extrusion parameters such as plunger speed and solid fraction on the extrudability, microstructure, and mechanical properties of extruded samples were investigated. The results show that the plunger speed and solid fraction of the semi-solid metal need to be carefully controlled to produce complete extruded parts.