Sintering and lamination characteristics of Fe-Cu atomized powder have been investigated to meet requirements on recycling of automobiles and manufacture of lightweight structure. The greentape laser sintering method using Nd:YAG pulse laser and powder tape called "greentape" is employed for the fabrication of Fe-Cu porous structure. Extensively investigated is influence of copper content and laser parameters, such as voltage, pulse width and average power, upon the state of liquid sintering or both surface texture and tensile strength of the sintered specimens. A gas-atomized Fe-2mass%Cu powder (20um in mean diameter) is superior to the Fe-15mass%Cu one in monolayer tensile strength, but contains many pores. It is successful to laminate 16 layers of the greentape (190 jam in thickness each) at a voltage of 198V, a pulse width of 2.0ms and an average power of 13W. Porous structure can be controlled by altering these laser parameters as well as by varying copper content.
