<p>Metal deposition technologies allow for significant enhancement of material surface properties. However, conventional deposition technologies are limited by spatial and equipment-related constraints, making simple and efficient surface improvement difficult. To address this, this study adopts a top-down composite synthesis strategy to develop an aluminum-based energetic material composite structure suitable for diverse application scenarios. By employing electrical excitation to induce redox reactions within the material, liquid metal is generated and subsequently deposited in situ upon cooling and solidification, thereby enabling surface modification. This method primarily forms a ‘super Cu alloy’ (Cu–WC–Co–Cr) on the substrate surface, which exhibits both ultrahigh electrical conductivity and ultrahigh hardness. The deposited layer shows a resistivity of less than 2.5 × 10⁻⁶ Ω cm (close to that of pure copper) and an average hardness exceeding 550 HV (significantly higher than conventional copper alloys). The reaction mechanisms, interfacial bonding behavior at the deposit cross section, and elemental diffusion patterns were systematically investigated. The results indicate that the deposited layer possesses high electrical conductivity, excellent corrosion resistance, and superior wear resistance in the direction normal to the interface. This work provides a simple, cost-effective theoretical and technical foundation for the manufacturing of wear-resistant sliding components used in high-current-density applications.</p> Graphical abstract <p></p>