Al/Sn-Bi core-shell spheres, which have potential for use in advanced electronic packaging, were fabricated in one step via phase separation by spraying liquid (Al 0.345 Bi 0.655 ) 67.8 Sn 32.2 alloy into silicone oil. The core-shell spheres changed morphology from three-layer to concentric or eccentric dual-layer type with decreasing melt superheat and increasing oil temperature. The spheres are Al-rich in the core, covered with a Sn-Bi-rich periphery, showing a two-stage melting behavior suitable for electronic packaging. The (Al 0.345 Bi 0.655 ) 67.8 Sn 32.2 alloy was identified through thermal analysis to undergo liquid-phase separation, monotectic reaction, and eutectic reaction one after another during cooling. Finally, the solidification path of (Al 0.345 Bi 0.655 ) 67.8 Sn 32.2 alloy was analyzed and was schematically illustrated.