The microstructure and morphology of 70% TiO2-30% Al, 70% TiO2-30% A1(2)O(3), 55% TiO2-045% Al and 55% TiO2-45% A1(2)O(3) composite powders were prepared by Smart Mini Ball Miller. They are characterized by XRD, SEM, EDAX, FTIR and TG/DSC. The XRD results showed that composite powders were mainly in the amorphous anatase phase with high crystallinity. The SEM study of composite powders reveals the average particle size is 100 20 nm. In FTIR, peaks observed at around 460 cm(-1)-560 cm(-1) represent bending vibrations of Ti-O-Ti groups in the composite powders. In TG/DSC analysis, there is weight gain in TiO2-Al composite powders where as weight loss in TiO2-A1(2)O(3) composite powders. Finally, microstructure and characterizations of the composite powders during ball milling were investigated to propose an optimal route for obtaining composite powders suitable for thermal spray process. (C) 2017 Elsevier B.V. All rights reserved.