Abstract: The process technology combining rolling-bonding technique with powder metallurgic foaming to prepare AFS (aluminum foam sandwich) was studied. Discusses the effect of the process technology applied to both face plate and core powder on the powder compactness, and it in relation to foaming effect. The foaming mechanism of AFS through the rolling-bonding process was found preliminarily. The results showed that the rolling process can provide very high compactness of core powder which decreases greatly the loss of H2 released from the foaming agent TiH2 in AFS during foaming. Thus, the foaming power is so sufficient that the defects such as bubble-free layer and large-size connected holes hardly occur. When the content of TiH2 is 1wt% the ideal foaming structure can be got after rolling-bonding and foaming processes to decrease production cost. AFS thus made has high flexural strength and other better mechanical properties as verified by three-point tests.