| Summary: | In this paper, the influence of mechanical milling on the microstructural evolution and magnetic properties of Al<sub>82</sub>Fe<sub>14</sub>Ni<sub>4</sub> alloys prepared by mechanical alloying is investigated. The elemental powder mixture was processed under argon gas at 250 rpm and 350 rpm using a planetary ball mill. The powder particles experienced severe deformation, fragmentation and mutually cold-welding during the collisions of the balls. The diffraction peaks of the Al, Fe and Ni phases gradually disappeared during the milling process, and a halo peak corresponding to the amorphous phase formed. The amorphization of powders milled at 250 rpm was slower than that of 350 rpm. These alloys achieved a fully amorphous structure after milling for 60 h. The amorphous powder alloy milled at 350 rpm exhibited higher thermal stability compared with that of an alloy milled at 250 rpm. The saturation magnetization and coercive of the milled Al<sub>82</sub>Fe<sub>14</sub>Ni<sub>4</sub> alloy powder were decreased following the formation of a para-magnetic amorphous phase. The highest compressive strength, about 710 MPa, was obtained for the Al<sub>82</sub>Fe<sub>14</sub>Ni<sub>4</sub> alloy sintered at 600 °C by SPS.
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