Knowing that you probably can't redo the voice acting at this late date, I was wondering if there were some easy things you could do to spruce it up without that much work. For example, why don't you pass all of DK's voice recordings through a filter to make them deeper. That will definitely make him sound scarier, like he should be. If he doesn't sound quite human after the filtering, that's fine. He's a knight from a realm of despair, so he shouldn't sound like my next door neighbor.
If not better voice acting, more dialog could also help set the tone with DK. What makes a great plot is the drama and the human interest. This unlikely combination between a good human and a Death Knight isn't played up at all, at least not in the demo. I should be made to feel how strange and uncomfortable this makes the characters with a little extra dialog at random spots. For example, 10 minutes into the game the following conversation could be triggered:
DK: I don't know if I can take this much longer. To be so close to a miserable human and not be able to cleave his flesh. My sword hand quivers at the thought of freeing your soul from that miserable carcass you call a body.
Character: Say it, don't spray it, Death Knight. This will be a very long journey if I must wipe your saliva from my face each time you start feeling hostile.
DK: Watch your tongue with me, human! I would feed you your own liver just to ask you how you like the taste, were it not for this petty curse that binds us. Just remember that.
The full game might already have this, but some occasional attempts to get DK to open up would also be cool. Just as an example:
Character: What do you like to do with your time, Death Knight? I mean, before we got bound up together?
DK: I serve at the bidding of my masters. That is all you must understand.
Character: Would sharing a detail or two kill you? Does conversation have to be a walk through mud with you?
DK: Fine. This one time, at death camp, I tore apart a newborn baby in front of her parents, at the bidding of my masters who thought they needed to be taught a lesson. Is there naught else you wish to know?
Character: No, um. That'll be it. Thanks.
Atlas