Producing titanium alloy materials through reduction of titanium tetrachloride

A process for producing a titanium alloy material, comprising:

• adding TiCl4 to an input mixture at a first reaction temperature such that at least a portion of the Ti4+ in the TiCl4 is reduced to a first intermediate reaction mixture, wherein the input mixture comprises aluminum, optionally AlCl3, and, optionally, one or more alloying element chloride, and wherein the first intermediate reaction mixture comprises an AlCl3-based salt solution that includes Ti3+;
• heating to a second reaction temperature such that at least a portion of the Ti3+ of the first intermediate reaction mixture is reduced to a second intermediate reaction mixture, wherein the second intermediate reaction mixture is an AlCl3-based salt solution that includes Ti2+, wherein adding TiCl4 to the input mixture at the first reaction temperature and heating to the second reaction temperature are performed sequentially in a reaction process;
• and
• further heating the second intermediate reaction mixture to a third reaction temperature such that the Ti2+ forms the titanium alloy material via a disproportionation reaction, wherein the third reaction temperature is about 250° C. to about 650° C.

A process for producing a titanium-containing material, comprising:

• mixing Al particles, AlCl3 particles, and, optionally, particles of at least one other alloy chloride to form an input mixture;
• adding TiCl4 to the input mixture;
• reducing Ti4+ in the TiCl4 in the presence of the input mixture at a first reaction temperature to form a first intermediate reaction mixture comprising Ti3+, wherein the first reaction temperature is lower than about 150° C.;
• thereafter, drying the first intermediate reaction mixture at a drying temperature of about 160° C. to about 175° C.;
• and
• thereafter, reducing the first intermediate reaction mixture comprising Ti3+ in the presence of the input mixture at a second reaction temperature to form a second intermediate reaction mixture comprising Ti2+, wherein the second reaction temperature is about 160° C. to about 250° C.

A process for producing a titanium alloy material, comprising:

• adding TiCl4 to an input mixture at a first reaction temperature such that at least a portion of the Ti4+ in the TiCl4 is reduced to a first intermediate reaction mixture, wherein the input mixture comprises aluminum, optionally AlCl3, and, optionally, one or more alloying element chloride, and wherein the first intermediate reaction mixture comprises an AlCl3-based salt solution that includes Ti3+;
• and
• heating to a second reaction temperature such that at least a portion of the Ti3+ of the first intermediate reaction mixture is reduced to a second intermediate reaction mixture, wherein the second intermediate reaction mixture is an AlCl3-based salt solution that includes Ti2+, wherein adding TiCl4 to the input mixture at the first reaction temperature and heating to the second reaction temperature are performed sequentially in a reaction process;
• and
• thereafter, reacting the second reaction intermediate comprising Ti2+ via a disproportionation reaction at a third reaction temperature in the presence of the input mixture to form the titanium alloy material, wherein the third reaction temperature is about 250° C. to about 650° C.