The effect of powder particle size on the microstructure, mechanical properties, and fracture behavior of Al-20 wt pct Si alloy powders was studied in both the gas-atomized and extruded conditions. The microstructure of the as-atomized powders consisted of fine Si particles and that of the extruded bars showed a homogeneous distribution of fine eutectic Si and primary Si particles embedded in the Al matrix. The grain size of fcc-Al varied from 150 to 600 nm and the size of the eutectic Si and primary Si was about 100 to 200 nm in the extruded bars. The room-temperature tensile strength of the alloy with a powder size Ͻ26 m was 322 MPa, while for the coarser powder (45 to 106 m), it was 230 MPa. The tensile strength of the extruded bar from the fine powder (Ͻ26 m) was also higher than that of the Al-20 wt pct Si-3 wt pct Fe (powder size: 60 to 120 m) alloys. With decreasing powder size from 45 to 106 m to Ͻ26 m, the specific wear of all the alloys decreased significantly at all sliding speeds due to the higher strength achieved by ultrafine-grained constituent phases. The thickness of the deformed layer of the alloy from the coarse powder (10 m at 3.5 m/s) was larger on the worn surface in comparison to the bars from the fine powders (5 m at 3.5 m/s), attributed to the lower strength of the bars with coarse powders.SOON-JIK HONG, Postdoctoral Research Fellow, and C. SURYANARAYANA, Professor, are with the