Abstract: A new Zn-based alloy with high Al content was prepared by spray forming and its microstructure and phase characteristics were investigated by scanning electron microscopy(SEM), transmission electron microscopy (TEM) and X-ray diffraction(XRD).It was found the alloy was consisting of Zn-Al eutectoid structure and nano-scale dispersed precipitation. Many anomalous pores were introduced into the alloy during deposition and porosity was over 10%. The best wear resistance was obtained for the heat-treated Zn-40Al-2Cu-6Si alloy under 2000N and 200r/min. It was found that the friction coefficient of the alloy decreased within creasing load.