The Spherical and densified of tungsten-based (W-Ni-Fe) alloy powder is of great significance to the improvement of physical properties such as the strength of powder-formed components for additive manufacturing. The effects of spray granulation and radio frequency (RF) thermal plasma treatment on the morphology and porosity of W-Ni-Fe alloy powder were studied by the spray granulation and radio frequency thermal plasma densification and spheroidization with high temperature. The research shows that the 96W-2.5Ni-1.5Fe ternary alloy powder formed by spray granulation has a loose microstructure, many internal voids and a rough surface. The comprehensive properties of the spray granulated powder can be significantly improved after the radio frequency thermal plasma treatment. The holes and looseness on the surface of spherical powder are alleviated, but there are also some micropores on the surface and internal with a few particles. The Ni and Fe phases between the W grains of the densified and spheroidized particles contain a relatively high content of W element.