Abstract: Cu-Ni-Al powders obtained by atomized technology were used to prepare porous Cu-Ni-Al sintered alloy used for molten carbonate fuel cell through hot press sintering technology. The morphology of Cu-Ni-Al spray powders and compressive property of the sintered alloys were studied, and the finite element method were used to study the morphology of porous sintered alloy.The results show that the average size of Cu-Ni-Al spray powders prepared by atomized technology was 39 μm, particle size distribution was very narrow and the morphology of the powders was almost nearly spherical. The powders were consisted of Cu phase and AlNi phase. The forming of Cu-Ni-Al sintered alloy prepared by hot pressing sintering was integrated, the compressive strength was 10 MPa, particles in the sintered alloy were tightly combined, and the pores displayed connected and open holes. The pore morphology had a great effect on the structure of porous Cu-Ni-Al sintered alloy. The more the pore edges number, the less stable structure the alloy. Under the same loading, the compression of triangle pores was minimum and that of circular pores was maximum.