Aluminum matrix composites provide an ideal solution for lightweight brake disks, but conventional casting processes are prone to crack initiation due to inhomogeneous reinforcement dispersion, gas porosity, and inadequate toughness. To break the conventional trade-off between high wear resistance and low toughness of brake disks, this study fabricated a bimetallic structure of SiC_p/Al–Fe–V–Si aluminum matrix composite and cast ZL101 alloy using friction stir lap welding (FSLW). Then, the microstructural evolution, mechanical properties, and tribological behavior of the FSLW joints were studied by XRD, SEM, TEM, tensile testing, and tribological tests. The results showed that the FSLW process homogenized the distribution of SiC particle reinforcements in the SiC_p/Al–Fe–V–Si composites. The Al₁₂(Fe,V)₃Si heat-resistant phase was not decomposed or coarsened, and the mechanical properties were maintained. The FSLW process refined the grains of the ZL101 aluminum alloy through recrystallization and fragmented eutectic silicon, improving elongation to 22%. A metallurgical bond formed at the joint interface. Tensile fracture occurred within the ZL101 matrix, demonstrating that the interfacial bond strength exceeded the alloy’s load-bearing capacity. In addition, the composites exhibited significantly enhanced wear resistance after FSLW, with their wear rate reduced by approximately 40% compared to the as-received materials, which was attributed to the homogenized SiC particle distribution and the activation of an oxidative wear mechanism.

SiC_p/Al-Fe-V-Si composites exhibit complex deformation behaviors at both room and high temperatures because of the presence of SiC reinforcement particles and numerous fine dispersed Al₁₂(Fe, V)₃Si heat-resistant phases. In this work, an artificial neural network (ANN) constitutive model was established to study the deformation behavior of SiC_p/Al-7.75Fe-1.04V-1.95Si composites over a wide temperature range based on uniaxial compression. Then, microstructural observation, finite element analysis, and processing maps were utilized to investigate the plastic workability. The results showed that the ANN model fit the experimental stress–strain curves with high accuracy, achieving an R² value of 0.999. The ANN model was embedded into finite element software to study plastic deformation behaviors, which indicated that this model could accurately compute the plastic and mechanical response during the compressing process. Finally, a thermomechanical processing diagram was developed, revealing that the optimal processing parameters of the SiC_p/Al-7.75Fe-1.04V-1.95Si composites were a deformation temperature of 450–500 °C and a deformation rate of 0.1–0.2 s⁻¹.