Mechanically milled pure aluminium powders were fabricated into bulk materials using back pressure equal channel angular consolidation (BP-ECAC) for four or eight passes at 373K. The bulk materials consolidated from 0 h and 4 h mechanically milled powders were characterised by Vickers hardness tests and density measurements. Thermal stability of the consolidated bulk materials was evaluated by isothermal heat treatments at 673K. The as-consolidated bulk material from the 0 h milled (i.e. unmilled) powder showed nearly full density. However, full density was not obtained with the 4 h milled powder even after eight passes. The HV values for the as-consolidated materials fabricated from the 0 h and 4 h milled powders after four passes and from the 4 h milled powder after eight passes were 57, 121 and 136, respectively. Softening was observed in the bulk material consolidated from the 0 h milled powder during the isothermal heat treatment. However, the hardness of the bulk materials consolidated from the 4 h milled powders after four and eight passes increased to maximum values of 137 and 141 after heat treatment for 28 h and 8 h at 673K, respectively. The maximum hardness was maintained for up to 100 h at 673K in both materials. The hardening and thermal stability in the bulk materials from the milled powders are attributable to dispersion strengthening of Al4C3 particles formed by solid-state reaction during the isothermal heat treatment.