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YOSHIHIKO HANGAI and TAKAO UTSUNOMIYA Closed-cell porous aluminum was fabricated by friction stir processing (FSP). Porous aluminum with a porosity of about 50 pct was successfully fabricated in a short time with low energy consumption and using inexpensive aluminum plates. Multipass FSP was efficient for fabricating high-porosity and high-quality porous aluminum. The results of the present study show that the FSP technique has high potential for fabricating porous aluminum at a low cost by a more environmentally friendly process.