Al-20Si-5Fe-3Cu-lMg alloy was synthesized by the 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, TEM (Transmission Electron Microscope) and HREM (High-resolution Electron Microscope), DSC (Differential Scanning Calorimetry), microhardness measurement, and tensile tests. The effects of Mn on the microstructural evolution of the highsilicon aluminum alloy after extrusion and heat treatment have been examined. The results show that two kinds of phases, i.e. S (Al2CuMg) and σ(Al5Cu6Mg2), precipitated from matrix and improved the tensile strength of the alloy efficiently at both the ambient and elevated temperatures (300℃). The tensile test results indicate that the spray-deposited Al-20Si-SFe-3Cu-1Mg alloy has better strength than the powder metallurgy processed Al-20Si-3Cu-1Mg alloy at elevated temperature.