Al-Fe alloy layers on heated steel sheet were made by Al powder spray for 30 minutes at $700^{circ}C$, $800^{circ}C$ and $1000^{circ}C$, respectively. As a results, for alloy layers formed at $700^{circ}C$ and $800^{circ}C$, main phases were brittle phase $FeAl_3 and Fe_2Al_5$, hardnesses were very high (Hv 700~800), corrosion resistances were good and surfaces were smooth, but wear resistances were bad. For alloy layer formed at $1000^{circ}C$, main phase was ductile phase $Fe_3Al$, hardness was low (Hv 300~400), corrosion and wear resistances were excellent, but surface was rough. Therefore, alloy layers that formed at $700^{circ}C$ and $800^{circ}C$ were heat treated at $1000^{circ}C$ for 10 minutes for the purpose of smooth surface and excellent wear resistance in this study. It was investigated that brittle phase $FeAl_3 and Fe_2Al_5$ of alloy layers fromed by Al powder spray at $700^{circ}C$ and $800^{circ}C$ turn into ductile phase $Fe_3Al$ by heat treated at $1000^{circ}C$ for 10 minutes without changing smooth surface. It was concluded that the alloy layers formed by Al powder spray on heated steel sheet at $700^{circ}C$ and $800^{circ}C$ for 30 minutes and heat treated at $1000^{circ}C$ for 10 minutes were excellent on wear and smooth surface.