In this study a hypereutectic aluminium-silicon alloy was synthesized by spray atomization and deposition technique. Microstructure characterization studies were performed to provide an understanding of the influence of spray processing on microstructure of the hypereutectic alloy. Ambient and elevated temperature tensile tests reveal the spray-processed alloy to have better strength and ductility than a conventional ingot metallurgy processed alloy having the same chemical composition. The quasi-static fracture characteristics of the spray-processed alloy is presented and discussed in light of processing and intrinsic microstructural effects.