Abstract The study focused on exploring powders sintered from mechanical milling of Ti6Al4V alloy pleats using the spark plasma method. Ti6Al4V alloy is a unique alloy with properties like low density and high specific strength that are widely used in the medical, automotive, and aerospace industries. However, producing this alloy requires high energy and high costs, and a significant amount of Ti6Al4V alloy plies are fabricated annually through machining. The aim of this research is to recycle Ti6Al4V alloy pleats and powder processing to enable their return to the production cycle. The pleats were milled using different parameters such as time, bullet to powder weight ratio, and machine type (ball mill, jar mill, and 3D mixer). Phase changes, morphology, and size of powder particles were eva‎luated using X-ray diffraction (XRD) and scanning electron microscope (SEM). The findings showed that with an increase in the system energy, the XRD peaks became wider, and the grain size obtained by Williamson-Hall's law decreased. The powders obtained with the Balmill planetary mill had impurities and aluminum alpha phase as the weight ratio of pellets to powder increased. The morphology of powders became more spherical, and the width of particle size distribution became narrower as the time increased, resulting in finer powders. The powders were then sintered with a spark plasma sintering machine at a temperature of 1000 degrees Celsius for 4 minutes and a pressure of 50 megapascals. The microstructure and mechanical properties of the samples were investigated. Grinding the powders resulted in a hardness of 588HV30 and a tensile strength of 1445MPa. The powders turned into a layer, and the amount of holes inside the sample decreased, which led to an increase in the density of the sample.

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