The present study concerns mechanical milling of commercially available CoNiCrAIY powder to produce nanocrystalline CoNiCrAIY and its consolidation by conventional and microwave sintering techniques. Detailed studies were undertaken to understand the effect of processing history (conventional and microwave sintering), materials parameters (as-received and mechanically milled for different time), and process parameters (temperature and time of sintering) on the density, microstructures, composition and phase distribution, coefficient of thermal expansion and high temperature oxidation resistance property. The density of the consolidated product increases with increase in milling time; increase in temperature of sintering in both conventional sintered and microwave sintered samples, with a maximum density achieved due to microwave sintering. There is a significant reduction in coefficient of thermal expansion due to sintering with a maximum reduction occurred when sintering is conducted by microwave sintering. Isothermal oxidation study showed a significant improvement in oxidation resistance due to nano-crystallization with a maximum improvement observed for 48 h milled sample microwave.sintered at 1100 degrees C for 48 h. (C) 2015 The Society of Powder Technology Japan. Published by Elsevier B.V. and The Society of Powder Technology Japan. All rights reserved.