AZ91 powder was consolidated by a two stage “in-situ” SPS cycle. Longer sintering times at 360 °C improved material cohesion while keeping fine grains. Al12Mg17 precipitation was subsequently controlled by an in-situ treatment at 200 °C. The in-situ treatment induced continuous and discontinuous Al12Mg17 precipitations. Proper control of the two stage SPS treatment led to optimum properties.