A process for producing a titanium alloy material, comprising: heating an input mixture to a preheat temperature, wherein the input mixture comprises aluminum, optionally, AlCl 3, and, optionally, one or more alloying element halide, wherein the halide of the one or more alloying element halide is chloride; introducing TiCl 4 to the input mixture at a first reaction temperature such that substantially all of the Ti 4+ in the TiCl 4 is reduced to Ti 3+ in the form of TiCl 3 complexed with metal chloride(s), wherein the reduction of Ti 4+ to Ti 3+ is an alumino-thermic reduction in a first zone of a reactor and is performed in an inert atmosphere having a pressure of 93.3 kPa to 506.6 kPa and at the first reaction temperature of 110°C to 200°C; thereafter, heating to a second reaction temperature such that substantially all of the Ti 3+ is reduced to Ti 2+ to form an intermediate mixture, wherein the intermediate mixture comprises a Ti 2+ salt, wherein the intermediate mixture contains dissolved Al in the Ti 2+ salt, but is substantially free of any particles of Al metal wherein substantially free means 0 atomic % up to 0.2 atomic %, wherein the reduction of Ti 3+ to Ti 2+ is an alumino-thermic reduction in a second zone of the reactor, wherein at least a portion of the Ti 2+ is in the form of TiCl 2 complexed with metal halide(s), wherein heating to a second reaction temperature is performed in an inert atmosphere, wherein the inert atmosphere has a pressure of 93.3 kPa to 506.6 kPa and the second reaction temperature is 180°C to 250°C, wherein the reaction of reducing Ti 4+ to Ti 3+ prior to the formation of Ti 2+ via the reaction of reduction of Ti 3+ to Ti 2+ are performed sequentially, and wherein the second reaction temperature is greater than the first reaction temperature; collecting the intermediate mixture as a solid or liquid in a storage vessel after the heating to the second reaction temperature; measuring the composition of the intermediate mixture; and adjusting the composition of the intermediate mixture by adding at least one alloying element; and introducing the intermediate mixture into a reaction chamber at a disproportionation reaction temperature to form the titanium alloy material from the Ti 2+ via a disproportionation reaction, wherein the Ti 2+ is reduced to titanium alloy via a disproportionation reaction at a temperature of 300°C to 900°C, and wherein the disproportionation reaction is performed in an inert atmosphere, wherein the inert atmosphere has a pressure of 101 kPa to 506.6 kPa. heating an input mixture to a preheat temperature, wherein the input mixture comprises aluminum, optionally, AlCl 3, and, optionally, one or more alloying element halide, wherein the halide of the one or more alloying element halide is chloride; introducing TiCl 4 to the input mixture at a first reaction temperature such that substantially all of the Ti 4+ in the TiCl 4 is reduced to Ti 3+ in the form of TiCl 3 complexed with metal chloride(s), wherein the reduction of Ti 4+ to Ti 3+ is an alumino-thermic reduction in a first zone of a reactor and is performed in an inert atmosphere having a pressure of 93.3 kPa to 506.6 kPa and at the first reaction temperature of 110°C to 200°C; thereafter, heating to a second reaction temperature such that substantially all of the Ti 3+ is reduced to Ti 2+ to form an intermediate mixture, wherein the intermediate mixture comprises a Ti 2+ salt, wherein the intermediate mixture contains dissolved Al in the Ti 2+ salt, but is substantially free of any particles of Al metal wherein substantially free means 0 atomic % up to 0.2 atomic %, wherein the reduction of Ti 3+ to Ti 2+ is an alumino-thermic reduction in a second zone of the reactor, wherein at least a portion of the Ti 2+ is in the form of TiCl 2 complexed with metal halide(s), wherein heating to a second reaction temperature is performed in an inert atmosphere, wherein the inert atmosphere has a pressure of 93.3 kPa to 506.6 kPa and the second reaction temperature is 180°C to 250°C, wherein the reaction of reducing Ti 4+ to Ti 3+ prior to the formation of Ti 2+ via the reaction of reduction of Ti 3+ to Ti 2+ are performed sequentially, and wherein the second reaction temperature is greater than the first reaction temperature; collecting the intermediate mixture as a solid or liquid in a storage vessel after the heating to the second reaction temperature; measuring the composition of the intermediate mixture; and adjusting the composition of the intermediate mixture by adding at least one alloying element; and introducing the intermediate mixture into a reaction chamber at a disproportionation reaction temperature to form the titanium alloy material from the Ti 2+ via a disproportionation reaction, wherein the Ti 2+ is reduced to titanium alloy via a disproportionation reaction at a temperature of 300°C to 900°C, and wherein the disproportionation reaction is performed in an inert atmosphere, wherein the inert atmosphere has a pressure of 101 kPa to 506.6 kPa.