Abstract: Al-4.5Cu-5Pb alloy was prepared by sand and chill casting. The same alloy was also spray deposited at a gas pressure of 1.6 MPa. The microstructural features exhibit a coarse to fine dendritic morphology for sand and chill cast alloys. Equiaxed grains were observed for spray fOrmed alloys. Wear testing employing a pin-on-disc type set-up, reveaIs considerably lower wear of spray deposited alloy compared to that of chill and sand cast alloys. The morphological features of wear track on specimen and debris indicated a mixed oxidative-cum-adhesive wear mechanisms for these alloys tested in the present investigation