The effects of the process-control agents (PCAs) stearic acid and methanol on the mechanical alloying (MA) of a nanostructured aluminum alloy (Al 93 Fe 3 Ti 2 Cr 2 ) have been investigated. The dependency of the powder-particle sizes, grain sizes, atomic-level strains, lattice parameters, formation of solid solutions, and microstructural evolution of the aluminum alloy on the types of PCAs and their concentrations have been studied using a variety of analytical instruments including X-ray diffraction scanning electron microscopy, and transmission electron microscopy. The results clearly indicate that prevention of excessive cold welding of Al particles can be achieved by the addition of a PCA at the expense of reductions in the grain size, formation rate of solid solutions, and rate of microstructural refinement, all of which are desired in MA of the Al alloy. Furthermore, a PCA that is more effective in preventing excessive cold welding will also impose more hindrance to the MA process. These phenomena have been discussed in the light of the adsorption of the PCA on the metal surface and the lubricating function of the PCA.

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