Abstract: Feasibility to produce flake aluminum powder from aluminum foil scrap by dry ball milling in inert nitrogen at mosphere with a few fraction of oxygen was investigated.It was found that under the micro-forging of falling balls,t he alu minum foil scrap was la minated,elongated,frag mented into small pieces of foil and finally for med flake powder.Bigger ball is beneficial to the milling of aluminum foil into the flake po wder due to the larger impact energy of the falling ball.Proper inter mediate suspension of the milling and cooling the mill in the first 25hours of milling brought about finer alu minum flake po wder than Stearic acid milling additive would reduce friction bet ween the foil or the balls and mill wall,thus reduce the milling efficiency and the proper amount of use was opti mized to be 3%.The fabricated alu minum flake po wder could be applied for fingerprint detection or aerate light-weight concrete.