Cold unidirectional compaction of smaller‐sized rapidly‐solidified (RS) and larger‐sized non‐rapidly‐solidified (N‐RS) aluminum alloy powders has been studied. The particle packing, plastic flow and interparticle bonding of the compacts were examined in detail. The pressure‐density‐strength (PDS) relationships of the compacts of RS and N‐RS powders were investigated, compared and discussed. Special effort was made to investigate the particle size fraction effect on the P/D/S relationships of N‐RS powder compacts.