A novel method to fabricate high strength and ductility Ti-3Al-5Mo-4.5 V alloy based on TiH2 and pre-hydrogenated master alloy powders

•Pre-hydrogenation of alloying powders is effective in increasing the element diffusion rate during sintering and final density of TC16 alloys.•Hydrogenated powder particles can get interlocked and shrink together, minimizing the volume mismatch between particles during compaction and sintering.•Ti atoms can increase traps for H atoms during hydrogenation, enhancing the hydrogenation degree of alloying powders added with Ti.•By using the novel master-alloy pre-hydrogenation (MAPH) method, the sintered TC16 alloy achieves a superior combination of strength and ductility.