The effects of processing parameters on the flow behavior and microstructures were investigated in hot compression of powder metallurgy (P/M) Ti-6Al-4V alloy. The alloy was fabricated by a blended elemental (B/E) approach and it exhibited lamellar α+β microstructure. The hot compression tests were performed in the range of temperature 800-1000°C with 50°C intervals, strain rate 10⁻⁴-10 s⁻¹, and strain up to 0.5. At 800-950°C, continuous flow softening after a peak stress was observed with strain rates lower than 0.1 s⁻¹. At strain rates higher than 1 s⁻¹, rapid drop in flow stress with strain hardening or broad oscillations was recorded. The processing map of P/M Ti-6Al-4V was designed based on the compression test and revealed the peak efficiency at 850°C and 0.001 s⁻¹. As the processing temperature increased, the volume fraction of β phase was increased. In addition, below 950°C, the globularization of phase at the slower strain rate and kinking microstructures were found. Based on these data, the preferred working condition of the alloy may be in the range of 850-950°C and strain rate of 0.001-0.01 s⁻¹.

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