Disclosed herein is a process that includes: (a) providing a powder blend comprising (1) one or more hydrogenated titanium powders containing around 0.2 to around 3.4 weight % of hydrogen, and (2) one or more master alloys, comprising Al, V, or a combination thereof, (b) consolidating the powder blend by compacting the powder blend to provide a green compact, (c) heating the green compact to a temperature ranging from around 400° C. to around 900° C., thereby releasing the majority or all of the hydrogen from the hydrogenated titanium, and partially sintering the green compact without fully sintering it, to obtain a partially sintered article having a density of about 60% to about 85% of theoretical density, (d) sizing the partially sintered article at a temperature at or around room temperature to obtain an sized article having a density of about 80% to about 95% of theoretical density, (e) heating the sized article in vacuum thereby sintering the article to form a sintered dense compact having a density of 99% of theoretical density or higher.