सार /ABSTRACT : Electrical explosion (EEW) technique of thin wire is one of the most efficient methods to produce metal nanopowders with a higher level of purity. Nanopowder of eutectic Al-Mg alloy was synthesized using electrical explosion of thin plates. Thin plates of Al-Mg eutectic alloy were cut from the thin casting by low-speed diamond cutter and thickness is further reduced by polishing using emery sheets of coarse and finer grades. A voltage doubler circuit is used to charge the capacitor to elevated voltage and is discharged through the metal plate in a wire explosion chamber filled with argon/helium gas at 100 KPa pressure. The nanopowder obtained is examined using Scanning Electron Microscope (SEM) and Transmission Electron Microscope (TEM). X-ray diffraction (XRD) analysis confirms peaks corresponding to inter-metallics.SEM and TEM images substantiate the spherical structure of the nanoparticles and diameter of particles ranges from 20 nm to 95 nm. Thermo Gravimetric Analysis (TGA) and Differential Scanning Calorimetry (DSC) of the powder shows offset temperature of melting around 442.18 °C and an endothermic peak temperature of 450°C, which are in consonance with the melting temperature of eutectic compositionofbinaryAl-Mgsystem.Hypoeutectic composition of Al-Mg alloy binary system was established as a stabilized composition for production of Al-Mg alloy nanopowders for fabrication of solid propellant. Nanopowder of hypoeutectic Al-Mg alloy was prepared by high voltage Electrical Wire Explosion Process (EEW) under inert Argon and Helium gas environment with chamber pressure of 25 kPa and 50 kPa. The thin wires for explosion were prepared by Electrical Discharge Machining (EDM) process from Al-Mg alloy cast. XRD analysis of powder produced and alloy cast was performed to compare the phases present. SEM images were taken for studying the shape and structure of the nanopowder particles and Energy Dispersive Analysis of X-rays (EDX) was performed for affirming elemental composition of alloy powder. Morphological characteristics of nanopowders were analyzed by TEM images and the particle diameter was found ranging from10 nm to 90 nm. Highly magnified TEM images were obtained to analyze the formation of various phases in the powder. TGA-DSC measurements were made to substantiate the low melting nature of Al-Mg alloys predicted by Al-Mg binary phase diagram with an offset temperature of melting 460 °C, which is much closer to the eutectic melting point (450 °C) ofAl-Mgbinarymetalalloy. Solid propellants were prepared by adding the alloy nano powder as an energetic additive element with bimodal ammonium perchlorate (AP) and Hydroxyl Terminated Polybutadiene (HTPB) propellant formulations. Burning rates of the propellant are compared with micro aluminised propellants and propellants with micro Al-Mg powder with the same composition. Mean burn rate of 22.03 mm/sec was obtained at a pressure level of 90 bar with nano Al-Mg powder and 20.4 mm/sec with micro Al-Mg powder compared to mean burning rate of 10.03 mm/sec at 80 bar pressure for aluminised propellants. The improved mean burn rate of propellants containing Al-Mg alloy nanoparticles could be accounted for the reduction in size of the alloy particle and selective melting of eutectic phases along with magnesium giving heat feedback to high-temperature reaction zone augmenting further reaction of metal particles.