Abstract: The typical heat-resistant FeCrAl alloys have recently been developed as the high-temperature resistant porous materials which are applied widely in the fields of coal-gas purification and high-temperature catalyst carrier. The aluminum mass fraction has an important influence on the pore structure, mechanical property, and oxidation resistance of the FeCrAl alloy porous materials prepared by the reactive synthesis. In this paper, a series of Fe‒20Cr‒xAl alloy porous materials (x=0~20%, mass fraction) were prepared by the reactive synthesis using the mixed Fe, Cr, and Al elemental powders as the raw materials. The effects of Al mass fraction on the phase composition, pore structure, mechanical property, and oxidation resistance of the FeCrAl porous materials were investigated. The results show that, the synthesized Fe‒20Cr‒5Al porous materials possess the superior pore structure and mechanical property, and show the optimal oxidation resistance and mechanical property stability in the high temperature oxidation experiment at 600~800 ℃.