Abstract: The effects of heating duration and mould temperature on thixoformability, microstructure and wear behavior of AZ91D alloy were investigated. The results indicated that the optimum heating duration at 585℃ was 90 min and mould temperature was 350℃. A compact microstructure with small and spherical primary particles was obtained under these conditions and the resulting alloy had the best wear resistance. Compared with the permanent mould casting, the thixoforming process decreased the porosity significantly, and improved the wear resistance obviously.