This paper investigates the capability of the FFC-Cambridge process of producing metallic hafnium powder that can meet commercial standards. The results show that the reduction in the core of the pellet is hindered in an intermediate step associated with the formation of CaHfO3. Doping the initial hafnium oxide with niobium oxides in the initial pellet prevents this blocking. The charge passed is much higher than that observed with undoped HfO2. The powder obtained after 36h of electro-deoxidation is an Hf-Nb alloy cubes with 0.8 wt.% oxygen content and 5-20 mu m size. (C) 2011 Elsevier Ltd. All rights reserved.