Ball-milled nanocrystalline Ti3RuFe powders were mixed with 1, 2, 4, 10 and 20 equivalents of Al and the mixtures were milled again for 20 h. The amount of Al atoms dissolved into the B2 structure of Ti3RuFe does not exceed 8-9 at %, the remaining being present as elemental Al into the powder mixture. During a subsequent treatment of the composite powder in alkaline solutions, the elemental Al is leached out, while Al solutes in the B2 structure are not affected. An examination of the surface by scanning electron microscopy reveals that the leached powder has a highly porous surface structure. Surface area measurements performed by BET measurements show that there is a tenfold increase in the effective surface area. Activated electrodes made from these porous materials show a significant decrease of the cathodic overpotential for hydrogen evolution in typical chlorate electrolysis conditions of about 80 mV.