Increase of Si content increases wear resistant properties of hypereutectic Al-Si alloys. However, large primary Si phase is inevitable in AlSi alloy when the alloy is produced by conventional casting processes, which deteriorate its machinability as well as its mechanical properties. The objective of this study is to produce graded Al/Al-Si nanocomposite coating onto an A1050 Al alloy substrate by mixing Al and Si nanoparticles with Supersonic Free-Jet PVD (SFJ-PVD). The SFJ-PVD has been developed as a new coating method in which a coating film is formed by depositing nanoparticles with very high velocity onto a substrate. This SFJ-PVD provides a high deposition rate and produces a mixture of different kinds of nanoparticles formed in different evaporation chambers on the substrate. The graded Al/Al-Si coating film is produced by depositing Al and Si nanoparticles formed in different evaporation chambers with the controlled evaporation rates of Al and Si respectively. A smooth, compact and defect-free microstructure is formed both at the interface between the substrate and the coating film and inside the coating film. The graded Al-Si coating film has very fine, varying from 10 to 20 nm in diameter, Si phases in Al matrix. It is confirmed with nano-indentation hardness tester that the graded Al/Al-Si coating film on A1050 substrate has graded hardness from 0.65 to 5.9 GPa corresponding to the gradual compositional change of Si up to Al-57.8 at%Si.