The microstructure characteristics and wear behavior of a spray-deposited (SD) and the hot compressed Al-28Si alloys were investigated and the results were compared with corresponding SD and as-cast alloys. The microstructure, hardness and wear properties of the spray-deposited alloy was studied using X-ray diffraction, optical microscopy, scanning electron microscopy (SEM), microhardness measurement and wear tests. The microstructures of the SD alloy were composed of refined and uniformly distributed primary silicon (Si) and the formation a fine eutectic phase at the inter particle boundaries of an equiaxed grain morphology of the aluminum (Al) matrix. The decrease in the porosity level and further refinement of primary Si and eutectic Si phases in the hot pressed alloy. The wear tests indicate that the hot pressed spray formed alloy showed good wear resistance compared to both the SD and as-cast alloys. The improvement in the wear behavior is discussed in the light of microstructure evolution by the spray-deposition process. The worn surfaces were characterized by SEM-energy dispersive X-ray spectroscopy (EDS).

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