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Near‐eutectic Al–Si alloys were produced by conventional casting and spray forming resulting in microstructural differences due to process dependent cooling rates. The as‐sprayed alloy exhibited fine equiaxed Si particles uniformly distributed throughout the matrix in contrast to the as‐cast alloy, which exhibited acicular morphology with relatively large needle‐like Si particles. The effect of Si morphology on the microstructural stress distribution of the as‐cast and as‐sprayed alloys was estimated by simulating uni‐axial tensile loads on microstructures using Object Oriented Finite Element code (OOF2). Microstructures of the as‐sprayed alloy experienced relatively low and uniform stress distribution, while the microstructural stress distribution in the as‐cast alloy was significantly influenced by the orientation of the needle shaped silicon particles.