The production of Al foams via a powder metallurgy (PM) route is attractive due to the ability to produce near-net-shape components. [1] This method involves mixing Al or Al-alloy powder with a foaming agent, typically TiH 2 , followed by compaction. Heating the compact above its melting point results in expansion, due to gas release from the decomposing foaming agent, leading to a closed-cell foam structure. [2] One major factor for successful foaming via the PM route is to ensure that precursors have a density close to the theoretical density, [3] that is, with little or no residual porosity after compaction. Since the majority of research and commercial activity in PM foams centres around the Al-Si system, where the compressibility of Al-Si alloy powders, or Al with Si added, is low, compaction methods involving the application of heat are employed in order that a reduction in the flow stress of the powder mixture is achieved. These methods, which include hot uniaxial compaction and hot extrusion of isostatically pressed compacts, are expensive, mainly due to higher energy requirements and reduced productivity, and contribute significantly to the prohibitively high cost of the precursor material. Precursors compacted in the optimum temperature range (400-500°C) [2] do, however, result in foams which show good expansions and structures, and it is generally accepted that compaction at elevated temperatures is a prerequisite for good foaming.Cold compaction can, however, be used to produce high density foamable precursors from soft pure Al powder. [3][4][5] By using this system, this study aims to separate the effects of exposure to elevated temperature, through heat treatment of the powders, and the application of pressure, by cold compaction. By understanding what factors in the hot compaction process dominate the foaming behaviour, it may be possible to identify alternative, lower cost processing methods.Results. Foaming behaviour: Figure 1 shows expansion plots for Al precursors that were hot compacted at different temperatures. The expansion behaviour in all cases can be seen to be typical of the foaming process, which involves pore initiation and growth, expansion to a maximum followed by collapse to a steady-state level. As the hot compaction temperature increases from 400 to 450°C, the maximum expansion also increases. When compaction is performed at 500°C, the maximum expansion increases further, to 400 %, and a delay in the rate of foam collapse is observed. Hot compaction at 550°C results in a significantly reduced foam expansion. Figure 2 shows the foaming behaviour for precursors made from either as-received Al powder or Al powder, which was heat treated for 60 min between 400 and 550°C, mixed with as-received TiH 2 and then cold compacted. A progressive increase in the maximum expansion is observed for powders heat treated at temperatures up to 500°C, with the largest maximum expansion of approximately 460 %.