Bi-metal material consisting of spray-formed Al-22 Si and ZL104 is a suitable candidate for applications in internal combustion engines. This research investigated the effects of surface treatment and appropriate gating system on the microstructures and mechanical properties in evaluating the optimal strategy for producing high quality bi-metal materials. The bi-metal materials were prepared using ZL104 gravity casting by different pouring types around the spray-formed Al-22 Si with varied surface treatments. The wettability between Al-22 Si and ZL104 was significantly improved when Zn coating was used to remove the natural oxide layer. This research also obtained the improved interfacial microstructures and interfacial bonding strength for materials when applying the appropriate pouring method. The hardness profiles of Al-22Si/ZL104 bi-metal were consistent with the observed microstructures. The average tensile strength of the bi-metal material with zinc coating is ~42.3 MPa, which is much higher than that with oxide film at ~10 MPa. The process presented is a promising and effective approach for developing materials in the automotive industry. Bi-metal material consisting of spray-formed Al-22 Si and ZL104 is a suitable candidate for applications in internal combustion engines. This research investigated the effects of surface treatment and appropriate gating system on the microstructures and mechanical properties in evaluating the optimal strategy for The high-quality bi-metal materials. The bi-metal materials were prepared using ZL104 gravity casting by different pouring types around the spray-formed Al-22 Si with varied surface treatments. The wettability between Al-22 Si and ZL104 was significantly improved when This research also obtained the improved interfacial microstructures and interfacial bonding strength for materials when applying the appropriate pouring method. The hardness profiles of Al-22Si / ZL104 bi-metal were consistent with the observed microstructures The average tensile strength of the bi-metal material with zinc coating is ~ 42.3 MPa, which is much higher than that with oxide film at ~ 10 MPa. The process presented is a promising and effective approach for developing materials in the automotive industry.