PURPOSE: To obtain an Al powder forged alloy having excellent characteristics under complicated shape and high performance without any defect of crack, etc., by executing diffusion heat treatment after forming a compacted body of Al alloy powder, which is compacted into simple shape, to the finished shape or the similar shape to this with hot forging at one shot having more than the specific reduction ratio.

CONSTITUTION: The Al alloy powder containing much alloy elements, particularly Fe, Ni, Si, etc., with rapid cooled solidifying method, is formed to the finished shape or the similar shape to this with the hot forging at one shot so as to execute large deformation at ≥30% the reduction ratio. Successively, the diffusion heat treatment or the forgings on and after the second shot having reduction ratio smaller than that of first shot are executed to the formed body. By executing the above diffusion heat treatment at 350-550°C for 1hr, the binding force between the particle is improved and alloy strength is improved and further, variety of the quality can be eliminated. Further, the forgings on and after the second shot may be executed at extremely small reduction ratio, because the alloy is already formed to the complicate finished shape with the forging at the first shot, and upset type metal flow is developed to improve the density, and the alloy strength can be improved.