The aluminium foam is reinforced by compositing ZrO2 ceramic balls with high hardness. The production process includes preparing precursor using NaCl particles and ZrO2 ceramic balls, infiltrating molten aluminium into precursor and cleaning NaCl particles. The defects presented during the process make the structure inhomogeneous and influence the performance of aluminium foam composite. The defects consist of inner and surface shrinkage caused by insufficient infiltration and inhomogeneous distribution of ZrO2 ceramic balls in the composite. By analyzing the forming mechanism, offering right control of process and choosing correct parameters, the sound aluminium foam composite was prepared. The optimum value of pouring temperature, preheating temperature of die and particles and the suction was determined as 740°C-760°C, 480°C-500°C and -0.04Mpa, respectively. The composite has the structure with 0.8-1.2mm pore size, 60-70% porosity and ZrO2 ceramic balls of 40 percent by volume. The research makes a basis for the application of the new aluminium foam composite.