Spherical shape Cu-Sn alloy powders with fine size for lithium secondary battery were directly prepared by spray pyrolysis. The mean size and geometric standard deviation of the Cu-Sn alloy powders prepared at a temperature of 1100 degrees C were 0.8 mu m and 1.2, respectively. The powders prepared at a temperature of 1100 degrees C with low flow rate of carrier gas as 51 min(-1) had main XRD peaks of Cu6Sn5 alloy and copper-rich Cu3Sn alloy phases. Cu and Sn components were well dispersed inside the submicron-sized alloy powders. The discharge capacities of the Cu6Sn5 alloy powders prepared at a flow rate of 51 min(-1) dropped from 485 to 313 mAh g(-1) by the 20th cycle at a current density of 0.1 C. On the other hand, the discharge capacities of the Cu-Sn alloy powder prepared at a flow rate of 201 min(-1) dropped from 498 to 169 mAh g(-1) by the 20th cycle at a current density of 0.1 C. (C) 2008 Elsevier B.V. All rights reserved.