The semi-solid slurry of AZ91D magnesium alloy was prepared by twin-screw stirring mixer, the microstructure and mechanical properties of semi-solid formed magnesium alloy AZ91D produced by rheo-diecasting and conventional liquid die casting were investigated, respectively. The strengthen mechanism of the semi-solid formed magnesium alloy after heat treatment was analysed by EDS. The results show that the mechanical properties of semi-solid formed magnesium alloy can be enhanced markedly by T4 and T6 heat treatment, owing to decrease of the porosity and less segregation in casting, brittle eutectic compounds dissolves gradually into α-Mg matrix, and the primary phase α-Mg decomposes in the course of heat treatment. In as-cast state, the tensile strength, elongation and hardness of semi-solid formed magnesium alloy AZ91D are 222MPa, 2.3% and 74 HBS, respectively. In T4 heat treatment state, the tensile strength and elongation are increased by 13% and 210%, and in T6 heat treatment state, the tensile strength and hardness are increased by 11% and 16%. The mechanical properties of castings formed by conventional liquid die casting are deteriorated distinctly after T6 heat treatment due to its porosity and crack defects.