Widespread application of mechanically alloyed powders requires production of the powder in tonnage quantities and also efficient methods of consolidating the powders into bulk shapes. All the consolidation methods generally used in powder metallurgy processes can also be used for mechanically alloyed powders. However, because the powder particles in the mechanically alloyed condition are smaller (typically a few microns, even though the grain size may be only a few nanometers) in size than those used in conventional powder metallurgy operations, some special precautions need to be taken to minimize their activity and high level of interparticle friction.

Conventional consolidation of powder to full density through processes such as hot extrusion and hot isostatic pressing normally requires use of high pressures and high temperatures for extended periods of time. Unfortunately, this results in loss of the benefits achieved due to the metastable effects or nanostructures obtained by MA. Therefore, novel and innovative methods of consolidating the mechanically alloyed powders are required.

Mechanically alloyed powders have been consolidated into useful bulk shapes by several processes. Because mechanically alloyed powders have a high hardness, cold compaction is not an option. Further, ODS alloys have been found not to densify during simple sintering. The most common method of consolidation is hot compaction followed by hot extrusion, or by direct hot extrusion at temperatures greater than half the melting point. This process could be used if one is not concerned with the loss of metastable effects, such as the crystallization of the amorphous phase in the powder. Some of the consolidation methods used for mechanically alloyed powders, both on laboratory and industrial scales, include hot isostatic pressing, powder rolling, Ceracon processing, plasma activated sintering, electrodischarge compaction, and explosive forming (shock methods). These operations are usually carried out at temperatures considerably lower than those used for conventional powders. For example, while conventional 7-TiAl powders are hot isostatically pressed at about 1100 °C, mechanically alloyed 7-TiAl powders could be consolidated to full density by hot isostatically pressing them at about 750 °C.

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