Power metallurgical (PM) processing has been employed to produce full-size disks of alloy 395MM where the ingot metallurgy processing was proven to be difficult. Alloy 395MM has a composition of Ti-46Al-4 (Nb, Cr, Mo)-0.2B-0.2C, and has been designed for disk application with improved resistance to oxidation and creep over previous disk alloys. In the PM process, pre-alloyed powder was produced by Ar-atomization at Crucible Research and consolidated through l hot isostatic pressing (HIP), followed by isothermal forging at Ladish. Preliminary experiments were conducted to produce and characterize medium-size compacts as part of development activity. Through multi-disciplinary group efforts, a disk weighing 220 kg and having a 71cm diameter was successfully produced as a full-scale forging. The forged disk was satisfactorily heat treated at Solar to produce fully-lamellar microstructures by employing a scale-up heat treatment cycle that had been formulated at Air Force by combining preliminary experimental results and process modeling. Extensive characterization work has been underway for the largest gamma forging ever produced. This presentation will brief the above processes, and discuss the progress made in the microstructure and mechanical behavior evaluation.