Tensile properties and deformation behavior of an extra-low interstitial fine-grained powder metallurgy near alpha titanium alloy by recycling coarse pre-alloyed powder

•An extra-low oxygen Ti alloy is prepared by a novel PM process using coarse pre-alloyed powder.•The process involves hydrogenation of the pre-alloyed powder, fast sintering and an immediate hot extrusion.•The PM process and a further annealing give rise to fine-grained α/βt composite structures with a high diversification of α variants.•The fine-grained α/βt composite structures render synchronously enhanced strength and ductility.