An attempt is made to synthesize the nano h-BN powders by high energy ball milling and also aluminium reinforced h-BN composite by powder processing route. The impact of ball milling time on microstructure and particle size reduction of h-BN powder was investigated by FESEM, FTIR, XRD, UV-vis diffuse reflectance spectroscopy and particle size analyser. It was indicated that high energy ball milling is effective up to 10 hours in reducing the particles size a further increase in time is resulting in agglomeration. Microhardness of the composite increases in proportion to increases in weight percentage of reinforcement, h-BN exhibited a poor sinterability without any accelerating agentand with tin addition up to 0.5% low melting point metal.TGA and DTA study shows that there is reduction in melting point from 641°C to 638 °C with addition of 2% weight fraction of h-BN. © 2016 Elsevier Ltd.