In this study, Ti-60Ta powders were produced by the plasma rotating electrode processing technique. The surface and internal microstructural morphologies, phase compositions, distances between dendrites and micro-hardness have been characterized for powders with different size ranges by SEM、XRD and Vickers micro-hardness methods. Results showed that the prepared Ti-60Ta powders exhibited major β phase and a small amount of martensitic α" and ω phases; the surface of larger particles appears isometric petal-shaped dentritic microstructures, while small particles exhibit refined dendritic microstructures. Particularly, fine acicular martensitic appearance was observed on the smaller particles. As the powder particle size decreases, the martensite phases increase and accordingly Vickers micro-hardness increases.