The official published version of this article can be found at the link below.The effect of the processing temperature on the microstructural and mechanical properties of Al-Si (hypoeutectic) alloy solidified from intensively sheared liquid metal has been investigated systematically. Intensive shearing gives a significant refinement in grain size and intermetallic particle size. It also is observed that the morphology of intermetallics, defect bands, and microscopic defects in high-pressure die cast components are affected by intensive shearing the liquid metal. We attempt to discuss the possible mechanism for these effects.Funded by the EPSRC