Bulk nanostructured Al-4 wt pct Cu alloy with high compression strength (879 MPa) was produced by mechanical alloying followed by vacuum hot pressing (VHP). The hot-pressed compacts were nanostructured with a grain size of 50 nm and were densified to more than 99 pct of the theoretical density. Contributions from different strengthening mechanisms were estimated using simplified models and were compared with the experiment.Ultrafine-grained (UFG) and nanocrystalline (nc) materials are increasingly being studied due to their improved mechanical properties. Bulk UFG or nc metals and alloys are commonly produced by methods based on severe plastic deformation (SPD). These SPD techniques, such as high energy ball milling, [1] equal channel angular pressing, [2] and high pressure torsion, [3] introduce very large plastic strains leading to grain refinement in coarse-grained powder or bulk materials. High energy ball milling can also be used to produce homogeneous supersaturated solid solutions from elemental powder blends. [4] The nc powders produced by high energy ball milling are usually consolidated into bulk by hot pressing, spark plasma sintering, and hot isostatic pressing followed by hot extrusion. [5,6] The Al-Cu alloys are important due to their high strength, which is achieved through precipitation strengthening. Recent work has shown that in precipitation-hardened UFG alloys, simultaneous improvement in strength and ductility could be achieved through SPD followed by annealing and aging. [7] There is very limited literature on the microstructure and mechanical properties of nanostructured Al-Cu alloys. Fogagnolo et al. studied solid solution formation in an Al-4.5 pct Cu alloy during milling and characterized the thermal stability during subsequent heat treatment. [8] The present work aims to synthesize nc Al-4 wt pct Cu binary alloy from elemental Al and Cu powder blend by high energy ball milling and to study the mechanical properties on bulk samples obtained via consolidation of the nc powders.Al-4 wt pct Cu alloy was prepared by mechanical alloying from high-purity (99.9 pct) elemental Al and Cu powders using a Retsch PM400 (RETSCH PM 400, Haan, Germany) high-energy planetary ball mill at 200 rpm and a ball-to-powder weight ratio of 14:1 using a hardened steel vessel and balls (10-mm diameter). Stearic acid (1 wt pct) was added as the process control agent. The loading and unloading of the powders were done in a glove box in argon atmosphere. Samples were taken at regular intervals during milling and analyzed using X-ray diffraction (XRD) with Cu K a radiation. From the XRD peak profile, instrumental broadening and K a2 components were subtracted and then the grain size (crystallite size) and lattice strain were estimated using the Williamson and Hall method. [9] Lattice parameters of Al were calculated from four peaks using the Cohen method. [10] The Cu concentration in solid solution was determined from the values of the lattice parameter using Vegard's law. Hardness variation as a function of milling ...