Effect of process parameters on micro and macro-properties of an Al-based nanocomposite prepared by means of mechanical milling

► Aluminum-Silica nanocomposites were fabricated using a solid-state route. ► The mechanical response was studied as a function of milling time and nano silica (NS) concentration. ► Further milling and high NS concentration had an adverse effect on the mechanical response of nanocomposites. ► TEM studies showed a uniform dispersion NS particles and good integration with the aluminum matrix. ► A thin layer of carbon covers the NS particles acting as a barrier, which avoids unwanted side reactions.