Al-18Pb and Al-22Pb alloys were processed by a rapid solidification process known as the spray deposition technique. Gaussian or bell-shaped deposits were obtained at a pressure of 10?bar, nozzle to substrate distance of 423?mm and substrate inclination angle of 0°. Deposits obtained from both alloys were warm rolled at a recrystallization temperature of 395?°C. Microstructural analysis of deposits showed that Pb is equally distributed in the Al matrix with 60% thickness reduction. For both alloys, the decrease in thickness percentage resulted in the decrease of hardness values. Porosity was lower in spray deposits of Al-18Pb alloy than the corresponding one from Al-22Pb alloy due to the casting and rolling defects. When the Pb percentage is increased from 18 to 22 in Al-22Pb compared with Al-18Pb, the wear rate increases abnormally. The frequency of wear and coefficient of friction values of Al-22Pb alloy were also higher when compared with those of Al-18Pb alloy.
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