AZ61 magnesium alloy wire with the diameters of 10 mm was fabricated by means of self-designed continuous rheo-extrusion equipment. Microstructure of the alloy can gradually be evolved from dendrites at the pouring entrance to the fine broken crystal

and to equiaxed and spherical grains at the extrusion zone due to the actions of kneading and shearing by the roll resulting in the sheared broken dendritic arm. During the extrusion forming process

solid phase structure in the central location has a slight deformation

while it has an evident deformation in the outside

and the ultra-fine grain structure can be generated in the meniscus. Prepared AZ61 magnesium alloy wire has desirable sectional microstructure

characterized by two-phase plastic flow with rational processing parameters.