This article intends to demonstrate synchronous in-process control of both external size and internal structure of ball processed particulates by regulation of the power cycle. For this reason, a coupled, nonlinear, computational model of the cycle elements is laid out, modeling joint and crack occurrences influencing the structure of particulates, along plastic distortion of spatial domains in their microstructure. The physics-based structural simulation emphasizes probabilistic representations of impactor collisions, particle assembly and population growth; While a simpler stochastic model of external particle features is based on statistical formulations of impact energetics, friction and plastic deformation effects, as well as bonding and fracture transformations of the particles during the process. 

The structural simulation reactions are calibrated and validated against the predictions of the stochastic model, as well as specially designed experiment data. Their real-time monitoring ability allows planning and control of the power cycle, utilizing substitute feedback from the predictions of the model, under a self-tuning regulation controller. This control scheme is tentatively implemented in low-energy planetary ball processing of Al and Ni powders for manufacturing of ignitable reactive bimetallic particulates, and the particle morphology and structureare found in concurrence with electron micrograph observations.