A novel process has been developed at Oak Ridge National Laboratory for the production of high silicon (Si) containing aluminum-silicon (Al-Si) alloy weld overlay on Al alloys. The main purpose of the overlay is to improve the wear resistance of the underlying alloy. The process is versatile enough to place the overlay only in critical areas, thus, greatly reducing the cost of a component. Instead of manufacturing a component from expensive high Si content 390 At alloy, the component could be manufactured from an inexpensive alloy, such as 319 At alloy, and the high Si, Al-Si alloy overlay could be placed in essential areas where high wear resistance was required. Test specimens comprised of the high Si, Al-Si alloy overlays on 319 At alloy have been processed to mimic the wear resistance of bulk 390 At alloys. Pin-on-disk wear tests have been performed, following ASTM standards, to quantify the wear resistance of the high Si, AI-Si alloy overlay with that of bulk 390 At alloy. Wear tests have also been performed on bulk 319 At alloy as a baseline. Lubricated and nonlubricated pin-on-disk wear tests were conducted utilizing 440 C stainless steel and 52 100 steel balls as the pin material. Also evaluated were the frictional forces during the wear tests, scratch hardness, microhardness, and the Hertzian contact pressures. From the tests conducted, the high Si, Al-Si alloy overlay shows potential as a replacement of bulk 390 At alloy for high wear resistant applications.