Abstract: Aluminum (Al) foams with different apparent densities were prepared successfully by powder metallurgy (PM) route. The effects of foaming process parameters on cell structures and expansion behavior were discussed in detail. The results showed that the temperature variation of foamable precursors is divided into three phases, i.e., linearly quick rising, constant and quick cooling, and the choice of furnace temperature depends on the linearly quick rising. The optimum foaming time and expansion rate are 120 sec and 434%, respectively, through the comparison of the cell structures and expansion behavior at different foaming times. Preheating precursors does not affect their temperature rising rates obviously but shortens the foaming time. The results of quasi-static compressibility tests showed that no obvious stress fluctuation is found during the collapse process of Al foams and the compressive strength, elastic modulus and compact stress all increase with apparent density.