Abstract: Aluminum foam sandwich(AFS) panels were successfully prepared by the powder-filled tube rolling process we developed with the commercial AlSi12 alloy, Mg and TiH2 powder used as raw materials, and the precursors prepared by such a process were systematically compared with that by the composite rolling process in macro-morphology, interfacial bonding and foam structure via a scanner with a resolution 300 dpi, SEM and micro-hardometer. The results showed that the aluminum foam panels prepared in this way can prevented them from crack propagation effectively and keep their complete shape with uniform compactness, thus providing the effective bonding between panels and core material. In the finished aluminum foam sandwich panels the foaming structures are complete and uniformly distributed.