A distinct modification of eutectic Si was observed in the selective laser melted AlSi10Mg. The eutectic Si particles were modified substantially and demonstrated a nanoscale size, a fibrous morphology with obvious ‘necking effect’. The modification mechanism and the influence of heat treatment on eutectic Si growth were explored. It was suspected that Si experienced the necking effect under a tensile environment due to the large temperature gradient and α-Al erosion during the SLM process. Upon heat treatment, the Si particles were spheroidised and distributed homogeneously. Under the synergistic action of Si crystal fragmentation and the continuous precipitation of saturated Si from the Al matrix, the coarsened and spheroidised eutectic Si were distributed homogeneously in the Al matrix.
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