In this work, micron porous aluminium (Al) specimens with various porosities were successfully prepared via a cold pressing-vacuum sintering-dissolution process (SDP) with water-soluble granules as space holders. Effects of the parameters of the sintering process on microstructure, density, and hardness were investigated. Results show that SDP was used to synthesise open-cell porous aluminium with uniform holes and enabled easy control of the microstructure porosity of porous aluminium. We also found that vacuum sintering and the addition of magnesium (Mg) improved the sintered behaviours. Based on our findings, the optimised sintering parameters (temperature and time) for porous aluminium are 650°C and 270 min, respectively.
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