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The Fe‐bearing hypereutectic Al‐Si alloys with/without Cr/(Cr+Mn) addition have been prepared by Spray Forming (SF) process. With 2 wt.% Cr addition, the short‐rod β‐Al5FeSi phase in spray‐formed Al‐25Si‐5Fe‐3Cu (wt.%, denoted as 3C) alloy can be substituted by particulate α‐Al(Fe,Cr)Si phase with sizes less than 5–6 μm. But small quantity of blocky β‐Al5(Fe,Cr)Si phase still appears in Cr‐added hypereutectic...
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