The spray droplets were deposited over a rotating copper substrate to achieve a disc shape preform. The thickness uniformity of the preform was found to depend on the preform distance from the nozzle, preform offset distance from the axis of the atomizer and inclination of the preform from the horizontal plane. Mathematical equations were developed to represent the thickness variation of the preform with aforementioned parameters. The porosity, hardness, strength, wear and microstructural studies of the Al-Si-Pb spray deposited alloys were conducted for different lead content, top to bottom...