Abstract: A method is disclosed for producing an energetic metastable nano-composite material as well as the energetic metastable nano-composite materials produced thereby. 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.

Abstract: There is disclosed a process and apparatus for generating uniform filler metal droplets of a size of from 50 to 1000 .mu.m for deposition onto small metal parts and components thereby producing localized heating and melting of the components to be joined.