Abstract: A1-20Si-5Fe-3Cu-1Mg alloy was synthesized by spray atomization and deposition technique.The microstructure and mechanical properties of the spray deposited hypereutectic Al-Si alloy were studied using optical microscopy, scanning electron microscopy, X-ray diffraction, and tensile tests. The effects of iron on the microstructural evolution of the high-silicon aluminum alloy after extrusion and heat treatment have been examined.The tensile test results indicate that the spray-deposited Al-20Si-5Fe-3Cu-1Mg alloy has better strength than the powder metallurgy processed Al-20Si-3Cu-1Mg alloy at elevated tempeate.