An intelligent material of Nb‐Al composite, is expected to produce intermetallics phase instantaneously upon collision with hypervelocity space debris to stop the crack propagation. Intermetallics‐free MA powder with Nb dispersion in Al matrix is targeted. Nb‐Al powders are mechanically alloyed using agate media. Mechanical alloying (MA) with agate media produced fine intermetallics‐free powder of Nb dispersion in Al matrix. Intermetallics‐free critical MA powder curve for agate media were established. The optimum critical agate MA powder of 200 rpm 132 hours had intelligent properties.

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