Abstract: An example method of preparing spherical composite powders is provided. The method includes introducing one or more starting material powders into an agitation mill. The method includes introducing a process control agent into the agitation mill, the process control agent including at least two immiscible liquids. The method includes agitating and milling the one or more starting material powders and the process control agent with the agitation mill to produce substantially spherical composite powders.

Abstract: A method is disclosed for producing an energetic metastable nano-composite material. Under pre-selected milling conditions a mixture of powdered components are reactively milled. These components will spontaneously react at a known duration of the pre-selected milling conditions. The milling is stopped at a time at which the components have been compositionally homogenized to produce nanocomposite powder, but prior to said known duration, and thereby before the spontaneous reaction occurs. The milled powder is recovered as a highly reactive nanostructured composite for subsequent use by controllably initiating destabilization thereof.