Abstract: The Al film was fabricated using mechanical coating technique (MCT) on ZrO₂ ceramic balls. The microstructure and composition of the film were examined by SEM and EDS. The effects of milling time, milling speed and ball-to-powder mass ratio on the thickness were investigated by L₉(3⁴) orthogonal test. The results showed that the factors, which affected the film thickness, were the ball milling rotating speed, ball milling time, and ball-to-powder mass ratio, from maximum to minimum. The maximum film thickness reached to 50μm and it was prepared if milling time is 10h, milling speed is 250r/min., and ball-to-powder mass ratio is 7∶ 1. The Al film was compacted, with low oxygen content and high purity.It was mechanically bonded well with ZrO₂ balls.