In this research, effect of the various mechanical milling process on morphology and microstructural changes of nano and micron Al-powders was studied. The milling of Al-powders was performed by both high energy and low energy ball milling process. The influence of milling (pulverizing) energy on the structural changes of Al-powders was studied. Al-nanoparticles were agglomerated during the MA and its size was increased with increasing milling while micron Al-powder gets flattened shape during high energy ball milling due to severe plastic deformation. Meanwhile, structural evolution during high energy ball milling of the nano powder occurred faster than that of the micron powder. A slight shift in the position of X-ray diffraction peaks was observed in nano Al-powders but it was un-altered in macro Al-powders. The variation in lattice parameters was observed only for nano Al powders during the high energy ball milling due to lattice distortion.
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