A process for producing a titanium alloy material, comprising: adding TiCl 4 to an input mixture at a first reaction temperature such that at least a portion of the Ti 4+ in the TiCl 4 is reduced to Ti 3+ to form a first reaction product, wherein the input mixture comprises aluminum, and, optionally AlCl 3 and/or optionally one or more alloying element halides; wherein adding the TiCl 4 to the input mixture is performed in an inert atmosphere having a pressure of 101 kPa (760 torr) to 199.98 kPa (1500 torr) and at a first reaction temperature of 100 °C to 165 °C; after TiCl 4 addition is stopped, heating the first reaction product at drying conditions to complete reduction of Ti 4+ or to remove all of any remaining TiCl 4 to form a first intermediate mixture, wherein the first intermediate mixture is an AlCl 3 -based salt solution that includes Ti 3+; heating the first intermediate mixture to a second reaction temperature such that at least a portion of the Ti 3+ is reduced to Ti 2+ in a second intermediate mixture, wherein the second intermediate mixture is an AlCl 3 -based salt solution that includes the Ti 2+, wherein the Ti 2+ is in the form of TiCl 2 complexed with AlCl 3; wherein heating the first intermediate mixture to the second reaction temperature is performed in an inert atmosphere having a pressure of 101 kPa (760 torr) to 506.6 kPa (3800 torr) and at a second reaction temperature of 180 °C to 250 °C; and further heating the second intermediate mixture to a third reaction temperature such that the Ti 2+ forms the titanium alloy material via a disproportionation reaction; wherein reacting the Ti 2+ via the disproportionation reaction to form the titanium alloy material is performed in an inert atmosphere having a pressure of 101 kPa (760 torr) to 506.6 kPa (3800 torr) and at the third reaction temperature of 300 °C to 900 °C. adding TiCl 4 to an input mixture at a first reaction temperature such that at least a portion of the Ti 4+ in the TiCl 4 is reduced to Ti 3+ to form a first reaction product, wherein the input mixture comprises aluminum, and, optionally AlCl 3 and/or optionally one or more alloying element halides; wherein adding the TiCl 4 to the input mixture is performed in an inert atmosphere having a pressure of 101 kPa (760 torr) to 199.98 kPa (1500 torr) and at a first reaction temperature of 100 °C to 165 °C; after TiCl 4 addition is stopped, heating the first reaction product at drying conditions to complete reduction of Ti 4+ or to remove all of any remaining TiCl 4 to form a first intermediate mixture, wherein the first intermediate mixture is an AlCl 3 -based salt solution that includes Ti 3+; heating the first intermediate mixture to a second reaction temperature such that at least a portion of the Ti 3+ is reduced to Ti 2+ in a second intermediate mixture, wherein the second intermediate mixture is an AlCl 3 -based salt solution that includes the Ti 2+, wherein the Ti 2+ is in the form of TiCl 2 complexed with AlCl 3; wherein heating the first intermediate mixture to the second reaction temperature is performed in an inert atmosphere having a pressure of 101 kPa (760 torr) to 506.6 kPa (3800 torr) and at a second reaction temperature of 180 °C to 250 °C; and further heating the second intermediate mixture to a third reaction temperature such that the Ti 2+ forms the titanium alloy material via a disproportionation reaction; wherein reacting the Ti 2+ via the disproportionation reaction to form the titanium alloy material is performed in an inert atmosphere having a pressure of 101 kPa (760 torr) to 506.6 kPa (3800 torr) and at the third reaction temperature of 300 °C to 900 °C.