Abstract In this study, fabrication of Fe-Al2O3 porous composite through combination of two non conventional material processing techniques of spark plasma sintering (SPS) and self propagating high-temperature synthesis (SHS) was investigated. Mixtures of Fe, Al and Fe2O3 powders, containing different amounts of each, were used as starting materials. Applying pulsed electric current to the powder was caused to the formation of Al2O3 and releasing of heat by reaction of Al and Fe2O3 according to: 2Al + Fe2O3 = Al2O3 + 2Fe. In addition, pulsed current flow through the powder heated up it by joule effect and supplied required energy for sintering. Fabrication of composite foam in time duration shorter than 5 minutes is the main feature of this process. It was found that increasing of Fe2O3 and Al contents in the primary mixture would result in an increase of Al2O3 and porosity at a constant sintering time.

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