In this paper, billets of Al-8.0Si-4.0Cu-0.5Mg alloys were manufactured by spray forming methods with suitbale parameters. The microstructures of as-sprayed and heat-treated alloys were analysed. The results showes that the alloy prepared with fine microstructures was obtained. The factors of formation of porosities were discussed during the spray forming process. Tests indicated the alloys had fine ,nechincal and wear resistance properties.