The application of high-energy elec. pulses has emerged as a promising technique for refining the grain structure, inducing solid phase transformations, and weakening the weave structure of cast AZ91D magnesium alloy, thereby enhancing its rolling performance during molding processes.This study investigates the comparative effects of elec. pulse treatment, homogenized annealing, and their combination on the microstructure and mech. properties of cast AZ91D magnesium alloy under various process conditions.Elec. pulse treatment offers several advantages over traditional homogenized annealing methods, including high energy efficiency, reduced processing time, and eco-friendly energy conservation.By avoiding excessive heating and material deformation, this method ensures improved integrity and stability of the material.This study provides an in-depth anal. of how changes in frequency and voltage during elec. pulse processing influence the microstructure and mech. properties of the alloy.Exptl. results reveal that optimal enhancements occur at a pulse frequency of 640 Hz and an output voltage of 240 V, which refine the β-Mg17Al12 phase from a large flaky structure to a fine worm-like form, resulting in significant grain refinement and reduced weaving strength.Consequently, there is a substantial improvement in mech. properties, with the specimens transitioning from brittle fracture to a mixed brittle-tough fracture mode.Tensile strength and elongation exhibit remarkable enhancements of 51.4% and 91.7%, resp., compared to untreated specimens.Furthermore, the combined application of elec. pulse treatment across all three processing conditions consistently yields superior results, while homogenized annealing followed by elec. pulse treatment leads to a decline in mech. properties.These findings highlight the efficacy of elec. pulse treatment as a viable method for enhancing the microstructure and mech. properties of cast AZ91D magnesium alloy, with significant implications for optimizing manufacturing processes in various industries.