Magnesium has been used as wheel materials in the automotive industry for more than 20 years. The magnesium wheels, which are lighter by 25% than aluminum wheels, provide easy controllability providing excellent road holding by the reduction of weight. The purpose of this work is to develop cast AZ91D alloy wheel by sand cast and permanent mold cast. The fluxless melting with the protective gas (SF 6 +CO 2 ) was Performed to eliminate oxidation of melt and impurity. The transfer of molten magnesium to the mold was done by using gas-pressurized Pump system through the heated pipe. The mechanical properites of AZ91D alloy wheel were investigated as a function of heat treatment, ingot composition.