Carbon fiber reinforced aluminum matrix (CF/Al) composites have great potential for lightweight applications, but their interfacial wettability is poor. In order to improve CF/Al interfacial bonding, a continuous copper coating was deposited on carbon fibers via electroless plating, and the effect of copper-coated carbon fiber (Cu@CF) content on composite microstructure and properties was investigated. The results showed that increasing Cu@CF content decreases density, coefficient of thermal expansion (CTE), and thermal conductivity, while hardness and tensile strength initially increase and then decline. Optimal comprehensive performance was obtained at 1 wt.% Cu@CF, achieving a tensile strength of 281.91 MPa, a friction coefficient of 0.7912, and a wear rate of 2.79 × 10−2 mm3/N·m. Previous studies have primarily focused on enhancing wettability or suppressing interfacial reactions using ZnO, Ni, or Al2O3 coatings, but the influence of coated-CF content has rarely been investigated. By revealing how Cu@CF content regulates Al2Cu formation and interfacial compatibility, a clear composition-structure-property relationship is established, providing practical guidance for designing high-performance lightweight Al-based composites.
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