Commercial vehicle pistons should have low thermal expansion and should be able to withstand deformation or mechanical stress. Aluminum alloys are suitable for pistons due to their light weight. However, as aluminum alloys have low strength and friction resistance, cast iron is added through the dipping process in order to increase the quality of pistons. However, the dipping process leads to defects such as defective bonding, void formation, and formation of an oxidation film at the junctions of the two materials due to differences in their properties, which adversely affects the impact resistance and mechanical strength of the product. A theoretical study on the metallurgical bond between the aluminum alloy and the cast iron insert in the piston was conducted to investigate the cause of the defects. The microstructure of the intermetallic bonding layer was observed using scanning electron microscopy and electron dispersive spectroscopy. In this study, defects were found in non-bonding and oxide films and several phases were generated corresponding to different parameters. It was found that processing time and temperature were the main causes of these defects.