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 a first intermediate mixture, wherein the input mixture comprises aluminum, optionally AlCl 3 , and, optionally, one or more alloying element chloride, and wherein the first intermediate mixture comprises an AlCl 3 -based salt solution that includes Ti 3+ ; wherein adding the TiCl 4 to the input mixture is performed in an inert atmosphere having a pressure of 93.3 kPa (700 torr) to 506.6 kPa (3800 torr) and at a first reaction temperature of 100 °C to about 165 °C; heating to a second reaction temperature such that at least a portion of the Ti 3+ of the first intermediate reaction mixture is reduced to a second intermediate reaction mixture, wherein the second intermediate reaction mixture is an AlCl 3 -based salt solution that includes Ti 2+ , wherein adding TiCl 4 to the input mixture at the first reaction temperature and heating to the second reaction temperature are performed sequentially in a reaction process; wherein heating the first intermediate mixture to a second reaction temperature is performed in an inert atmosphere, and wherein the inert atmosphere has a pressure of 93.3 kPa (700 torr) to 506.6 kPa (3800 torr) and at a second reaction temperature of 160°C to 250°C; and further heating the second intermediate reaction 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 a disproportionation reaction to form the titanium alloy material is performed at an inert atmosphere, and wherein the inert atmosphere has a pressure of 93.3 kPa (700 torr) to 506.6 kPa (3800 torr); and wherein the third reaction temperature is 250 °C to 650 °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 a first intermediate mixture, wherein the input mixture comprises aluminum, optionally AlCl 3 , and, optionally, one or more alloying element chloride, and wherein the first intermediate mixture comprises an AlCl 3 -based salt solution that includes Ti 3+ ; wherein adding the TiCl 4 to the input mixture is performed in an inert atmosphere having a pressure of 93.3 kPa (700 torr) to 506.6 kPa (3800 torr) and at a first reaction temperature of 100 °C to about 165 °C; heating to a second reaction temperature such that at least a portion of the Ti 3+ of the first intermediate reaction mixture is reduced to a second intermediate reaction mixture, wherein the second intermediate reaction mixture is an AlCl 3 -based salt solution that includes Ti 2+ , wherein adding TiCl 4 to the input mixture at the first reaction temperature and heating to the second reaction temperature are performed sequentially in a reaction process; wherein heating the first intermediate mixture to a second reaction temperature is performed in an inert atmosphere, and wherein the inert atmosphere has a pressure of 93.3 kPa (700 torr) to 506.6 kPa (3800 torr) and at a second reaction temperature of 160°C to 250°C; and further heating the second intermediate reaction 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 a disproportionation reaction to form the titanium alloy material is performed at an inert atmosphere, and wherein the inert atmosphere has a pressure of 93.3 kPa (700 torr) to 506.6 kPa (3800 torr); and wherein the third reaction temperature is 250 °C to 650 °C. <EOS>