Abstract: Flake zinc aluminum alloy powders were prepared by ball milling method using atomizing zinc aluminum alloy powders as raw material. The process parameters including ball grading, grinding agent, milling time and polishing time were optimized. The results show that the optimized process parameters were obtained when the mass ratio of steel ball in diameter of 9, 8, 6, 5, 3 mm was 1∶2∶2∶4∶4, the milling additives was a composite additives, milling time was 14 h and polishing time was 2 h. Flake zinc-aluminum alloy powders with a silvery white appearance were obtained at the optimized technical parameters, whose average diameter was 11.30 μm, apparent density was 1.33 g·cm-3, flaky degree was 98% and water surface coverage was 6 013 cm2·g-1.