Injection molding of the TC4 titanium alloy was investigated using the low-cost hydrogenationdehydrogenation (HDH) powders modified by jet-milled (JMed) as the raw material. Three types of powders

including HDH

jet-milled (JMed) HDH and gas-atomized (GA)

were compared in terms of maximum loading capacity

sintered density

impurity content

microstructure

and mechanical properties. Results showed that the particle sphericity of the JMed powder was significantly improved and thus enhanced the maximum loading capacity (volume fraction) by 6%

and exhibited higher sintering densification

as compared to the original HDH powders. After sintering at 1300 ℃ for 2 h

the density of the sintered parts using the JMed powders is 98.3%

higher than that using the original HDH powders (95.3%)

while equivalent to that using the GA powders (98.4%). The room temperature mechanical properties of the sintered parts using the JMed powders showed the tensile strength of 904.2 MPa

yield strength of 809.1 MPa

elongation of 8.14% respectively

much better than those using the original HDH powders. Furthermore

the strength of the sintered parts using the JMed powders demonstrated equivalent performance to that using the GA powders

indicating the quasi-spherical TC4 powders exhibiting a great potential for engineering applications.