Would Aluminium powder milled in an inert gas (N2 or Argon) be a better fuel? Al powder milled in air would be coated with oxide. Thought Experiment: Al milled in argon might explode on its own, on exposure to air?? the large surface area would oxidise promptly???

Not really, it would prevent it but it isnt worth the extra time and money.

CTR

You have a good point, but I agree with Genital-Warfare that it wouldn't be worth the effort.

The manufacture of aluminum powder is done in an inert atmosphere. Once you take it out, it forms an oxide layer. There is no point in using an inert atmosphere unless you are making your own powder. For example, spherical Al is made by vaporizing Al and condensing it in an inert atmosphere. Dark Al is pounded and then burned in an inert atmosphere. I saw a thing that gave more detail on the different processes, but I don't know where it was...