The microstructure of high strength PAN-based T700 carbon fibre (C f ) with pyrolytic carbon (PyC) coating was characterised. Effects of PyC coating on the surface of carbon fibres, interface characteristics, and mechanical properties of C f /AZ91D composites were evaluated. The results showed that the carbon fibres with PyC coating had higher surface roughness and higher graphitisation which were beneficial to ease hazardous interface reaction. C f -PyC/ AZ91D composites with an optimal PyC coating that is about 150 nm thick and has low texture exhibited ultimate tensile strength of 416 MPa, which demonstrated 35% improvement compared with the C f /AZ91D composites. The increase of mechanical properties of C f -PyC/AZ91D composites could be ascribed to a synergistic effect of the rough C f surface interlocking, an optimum interfacial bonding between fibres and matrix, and protection of fibres from a corrosive attack of the aluminium element in the matrix.