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Aluminum-based composite materials are frequently preferred in many new-generation engineering applications due to their high strength, wear and corrosion resistance, improvement of mechanical properties, machinability, and low density. Mechanical alloying has an important place in the production of composites with high properties in powder metallurgy, which is one of the composite material production methods. In this paper, the deformation of Al 2024 alloy powder, which is frequently used in the industry, is investigated by the three-dimensional ball mill. Three different rotation speeds (150, 200 and 250 rev/min), three different ball-to-powder ratio (5:1, 10:1 and 20:1) and three different milling times (30, 60 and 90 min) were used in the milling processes. Deformations in the powders were evaluated by particle size analysis and powder structure examination. The obtained results were analyzed with analysis of variance and regression method, three-dimensional graphics, and scanning electron microscope images. When the results are examined, the maximum percent areas covered by the deformed particles and maximum particle size among the selected experimental parameters were obtained at 250 rev/min, 20:1 ball-to-powder ratio and 60 min as 6.849% and 54 μ m. [ABSTRACT FROM AUTHOR]