Titanium (Ti) alloys can be thoroughly improved by introducing aluminum (Al) as an \(\alpha\) -phase stabilizer and tungsten (W) as a \(\beta\) -phase stabilizer as well as iron (Fe) for enhancing the strength and the creep resistance. In the current study, Ti–5Al–4W–2Fe alloy was especially synthesized to meet the essential requirements of the structural products of Ti-based alloys. Three different PM routes have been adjusted for investigating both densification and mechanical properties improvement of this alloy. The first approach was pressure-less vacuum sintering (PLS) at 1100–1300 °C for 1 h, which showed inadequate achievement of densification. Unfortunately, using PLS 96% of the theoretical density (TD) was recorded. However, using hot pressing (HP) and sintering-forging (IF) resulted in a successful full densification of 100% TD. It is worth mentioning that adding W particles resulted in an effective grain refinement of the sintered Ti alloy. More interestingly, HP-sintered specimens demonstrated higher strength and plastic compression compared to the other specimens. For instance, the yield and fracture strength of this specimen showed 1463 MPa and 2408 MPa, respectively, which is considered as a remarkable achievement compared to similar studies. Surprisingly, the most economical technique PLS sintering led to the best hardness of 700 HV, compared to 470 HV and 480 HV for the forged specimen and the HP-sintered specimen, respectively.
