The present study has investigated the influence of calcium process control agent on the mi-crostructure and mechanical properties of Ti-6Al-4V alloy fabricated by high energy ball milling and spark plasma sintering (SPS). For a comparison, Ti-6Al-4V, unmilled powder was also processed by SPS and the microstructural and mechanical properties were examined. A small quantity of calcium (0.3 wt%) was added during milling to obtain balance between the cold welding and fracturing phenomena, high process yield and low oxygen content. The milled and unmilled powder was sintered using SPS at 1250°C for 15 min, under a uniaxial pressure of 50 MPa. The microstructure of Ti-6Al-4V unmilled and milled powder sintered at 1250°C showed typical Widmanstatten structure and the average grain size values of milled Ti-6Al-4V were found to be lower compared to unmilled Ti-6Al-4V. The samples sintered at 1250°C from the Ti-6Al-4V powders milled with calcium (0.3 wt.%) showed high yield strength (964 MPa) and ultimate tensile strength (1153 MPa) and low elongation (5%) when compared to unmilled Ti-6Al-4V showed yield strength (875 MPa) and ultimate tensile strength (1057 MPa) and elongation (15%). The main reason for increase of yield and ulti-mate strength after milling was due to fine grain size.