Porous aluminum (Al) was fabricated by a tool traversing friction powder compaction process with the sintering and dissolution process. In this process, a mixture of Al powder and NaCl as spacer particle was the starting material. After the powder mixture was placed in a mold, sintering was conducted only by the traversing of a rotating tool. Namely, no external heat source was used in fabrication of porous Al except for the friction heat generated by the traversing of the tool. In this study, increasing in size of porous aluminum was conducted by applying multi-pass process. Fabricated porous Al had a length and width equal to the tool traversing area. By a X-ray computing tomography observation, fabricated porous Al had uniform pore distribution. In a compression test, it was found that fabricated porous Al had almost the same mechanical properties, regardless of the position in the tool traversing area.