Abstract:NaCl beads were prepared using starch, distilled water and NaCl powders as raw materials.The raw constituents were mixed to form a colloidal salt paste and then thermal treated in 70°C oil under vigorous stirring, high spherical NaCl beads were obtained under the cutting action of the blender. Afterwards, the “fried” NaCl beads with a particle size distribution of 0.4-2.4mm were calcined and sintered at 740°C, and thus the high purity NaCl beads with small amount of micro-pore (pores size about 10-20μm) on the surface were obtained. The 0.6-1.0mm salt beads were selected to form a “salts bed” in a steel die and the aluminum powder was filled into “salt bed” gap via a tapping method by the Autotap instrument.The tapped mixture was cold pressed under 200MPa to obtain the green compact parts. Then the salts were dissolved and removed in distilled water and three-dimensional open-cell green Al foam with controllable structure and highly reproducibility was derived. After sintering at 460 °C for 2 h, the final Al foam was obtained and its relative density and porosity were 0.217 and 78.3%. The number of connectivity windows between cellular aluminum cells is 4-6 on average, and the window size is about 120-200 μm. The compressive load-displacement curve shows that the aluminum foam undergoes an elastic deformation stage - the plateau stress area - the stress steep increase stage, The curvemanifest typical foam metal compression mechanical properties, and its compressive strength and Young''s modulus are 2.42 MPa and 0.38 GPa.