In this study gas atomisation and spray deposition of a series of AlFeVSi alloys were carried out. Traces of transient liquid were observed as lamellar structure in the middle of the specimen. The heat transfer conditions of this structure were modelled by finite difference calculation. Metallographic specimens for optical microscopy were prepared from the preforms formed in these processes. Optical microscopy showed the presence of dispersoids in the specimens. The dispersoids were characterised as AlFeVSi cubic phase by X-ray diffraction analysis. SEM was used to examine the morphology of phases and quantitative element analysis to reveal the chemical composition of the dispersoids present. The one-dimensional mathematical model, which describes the heat diffusion during spray deposition, was solved using the finite difference method.