Powder metallurgy is a preferred method to fabricate aluminium foam. Fundamental elements are the aluminium powder and domestic salt powder or carbamide tablets. The later functioning as spacer where different percentage of the powder weights charged in the mold. Mixed Al with NaCl powders synthesized under 500MPa pressure at 550°C using a hot pressing system. Since the mixed Al powder and carbamide tablet cold pressed under 300MPa then synthesized at 150°C to yield porous bulk metallic raw Al foams. Pressing mode and spacer nature have severe effects on the mechanical and electrical properties. There is an assessment between the mechanical and electrical parameters; this will direct to operate nondestructive examining of the samples. Fabricated foams via two modes studied; cold and hot pressing that proved superiority to the former. Anomalous pores in the samples are at the lowest level with respect to cold pressing. The maximum bending strength of hot pressed foam was 17MPa, i.e. high energy bonding between powder particles. Compressive tests and electrical conductivity measurements of hot pressed foams carried out in parallel to measured relative density of 65% to 75%.

foaming, amorphous metals, mechanical properties, powder metallurgy, electrical conductivity, carbamide, replication process.