Highly expanded, low-cost aluminum-based foams were successfully produced via powder metallurgy using dolomite as foaming agent. Nickel additions (5–15 wt.%) were explored in order to reduce the temperature disparity between dolomite decomposition and the melting range of the metallic matrix. Specific Al–Ni compositions provide appropriate viscosities for effective encapsulation of CO₂ gas released during dolomite decomposition. A partial sintering step of compacted precursors was introduced prior to foaming, which resulted in high porosity levels (~86%) and significant volume expansion (~250%) in the final product. The partial sintering technique was a key determining factor in obtaining stable, highly expanded cellular structures with homogeneous pores, averaging 3 mm in size and being morphologically comparable with ALPORAS^TM foams.