Face centred cubic Ti-10 and 20Mg and Ti-6Al-4Mg (wt.%) alloy powders have been produced by high energy ball milling, under argon, of elemental powder mixtures containing a process control agent (PCA). Milling leads to a multi-disperse particle size distribution without affecting the particle morphologies. This affects the thermal stability of the powders and the green densities of compacts. The green densities varied in tandem with the d(10) sizes of the powders and went through a minimum at 20 h of milling. Milling for 20 h could be detrimental to powder consolidation and further processing. (C) 2010 Elsevier B.V. All rights reserved.