The effect of process variables during spray forming of a commercial Babbit alloy containing Pb74-Sn12-Sb11.5-Cu1.25-Ni0.75-Cd0.3-As0.2 on its microstructure and wear characteristics were investigated. Variation in atomization gas pressure from 0.6 to 1.2 MPa and nozzle to substrate distance from 0.2 to 0.4 m revealed considerable change in the nature of porosity and microstructural features of the spray deposits. The process variables during spray deposition were optimized to achieve microstructural homogeneity and refinement in second phase particles of this alloy. The wear study of both the spray formed and as-cast alloy under an applied load of 10 to 70 N and sliding velocity of 0.2 to 1.5 ms(-1) indicated two distinct regimes of mild and severe wear. In both the regimes, the spray-formed alloy consistently indicated a low wear rate compared to that of the as-cast alloy. In addition, the mild wear regime of the spray-formed alloy was extended to higher load and sliding velocity. Wear characteristics of the spray formed alloy is discussed in light of its microstructural features induced during spray deposition processing.