Open-cell porous Al alloy was fabricated by pressure penetration casting. The fabrication ofpreform was studied in detail. When forming temperature is about 700℃ and binder contentis about 10%, preform with high compressive strength is obtained. Good porous Al alloy withpore size (0.5-1.6 mm) and porosity (60%-80%) can be obtained under 100℃ superheatingof liquid metal and about 1.0 MPa applied pressure. The size of the largest sample is up to100 mm in diameter and 100 mm in height. With the help of SEM it was found that the obtainedmaterial is a three-dimension open-cell porous structure with well-distributed and connected witheach other pores. Finally theoretical analysis was carried out to explain the efect of fabricatingprocess. Open-cell porous Al alloy was fabricated by pressure penetration casting. The fabrication of preform was studied in detail. When forming temperature is about 700 ° C. and binder content is about 10%, preform with high compressive strength is obtained. Good porous Al alloy with pitch size ( 0.5-1.6 mm) and porosity (60% -80%) can be obtained under 100 ° C superheatingof liquid metal and about 1.0 MPa applied pressure. The size of the largest sample is up to 100 mm in diameter and 100 mm in height. With the help of SEM it was found that the obtained material is a three-dimension open-cell porous structure with well-distributed and connected witheach other pores. Finally theoretical analysis was carried out to explain the efect of fabricating process.