When using NaCl particles as a space holder to prepare gradient porous aluminum, some phenomena included uneven pore distribution, low through-pore rate, and interlayer crack. The interlayer comparative study found that large NaCl particles were difficult to coordinate the compaction energy fully and form an excessively concentrated distribution, which further affects the volume expansion in the sintering process. This paper pro-posed for the first time that gradient porous aluminum with optimized structure can be prepared by adding the small space holder to the large space holder. Many problems caused by large NaCl particles in the process of compaction and sintering can be solved by this method and its structure.
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