Spark plasma sintering (SPS) process parameters were optimized in terms of densification, microhardness and corrosion resistance to develop a nano-structured Fe-18Cr-2Si ferritic alloy. The powders were mechanically alloyed (MA) in a planetary ball mill and subsequently SPS was carried out under different processing conditions. Powders and sintered samples were characterized using X-Ray Diffraction (XRD), scanning electron microscopy (SEM) and transmission electron microscopy (TEM). XRD phase evolution studies on ball milled powders confirmed the formation of a crystallized alloy after 100 h milling. XRD of sintered alloy confirmed the development of a nano-structured ferritic alloy with a crystallite size in the range of 20-40 nm. Maximum densification of 96.0%, Vickers hardness of 710 HV and pitting potential (E-pit = 430 mV(SCE)) was achieved at a sintering temperature of 1100 degrees C, for 15 min holding time, at 50 degrees C/min of heating rate and at an applied pressure of 60 MPa. (C) 2016 Elsevier B.V. All rights reserved.