Processes are provided for producing a titanium alloy material, such as Ti—Al alloys. In one embodiment, the process includes: heating an input mixture to a preheat temperature with the input mixture including aluminum, optionally, AlCl.sub.3, and, optionally ally, one or more alloying element halide; introducing TiCl.sub.4 to the input mixture at the first reaction temperature such that substantially all of the Ti.sup.4+ in the TiCl.sub.4 is reduced to Ti.sup.3+; thereafter, heating to a second reaction temperature such that substantially all of the Ti.sup.3+ is reduced to Ti.sup.2+ to form an intermediate mixture (e.g., a Ti.sup.2+ salt); and introducing the intermediate mixture into a reaction chamber at a disproportionation temperature reaction to form the titanium alloy material from the Ti.sup.2+ via a disproportionation reaction.

A metal titanium production apparatus includes: a reductor that subjects titanium tetrachloride to a reduction process in presence of bismuth and magnesium to obtain a liquid alloy containing titanium and the bismuth; a segregator that subjects the liquid alloy to a segregation process to obtain a precipitate; and a distillator that subjects the precipitate to a distillation process to obtain metal titanium, and the distillator sets an atmosphere so as to preferentially vaporize the bismuth attached to the precipitate and then sets the atmosphere so as to vaporize the bismuth forming the precipitate.

Process for producing a titanium alloy material, such as a titanium aluminum alloy, are provided. The process includes reduction of TiCl.sub.4, which includes a titanium ion (Ti.sup.4+), through intermediate ionic states of an AlCl.sub.3-based salt solution that includes Ti.sup.3+ and an AlCl.sub.3-based salt solution that includes Ti.sup.2+, which may then undergo a disproportionation reaction to form the titanium aluminum alloy.

A metal titanium production apparatus includes: a reductor that subjects titanium tetrachloride to a reduction process in presence of bismuth and magnesium to obtain a liquid alloy containing titanium and the bismuth; a segregator that subjects the liquid alloy to a segregation process to obtain a precipitate; and a distillator that subjects the precipitate to a distillation process to obtain metal titanium, and the distillator sets an atmosphere so as to preferentially vaporize the bismuth attached to the precipitate and then sets the atmosphere so as to vaporize the bismuth forming the precipitate.

Provided is sponge titanium produced by the Kroll method, in which the total of a chlorine content and a magnesium content is 350 ppm by mass or lower, and a filling density is 1.65 g/cm.sup.3 to 1.95 g/cm.sup.3. The present invention can provide sponge titanium for large ingot production that is difficult to cause problems due to chloride inclusion at the time of melting production of the large ingot by a melting method not associated with compression molding and has easy component control and also provide a method for industrially efficiently producing the sponge titanium.

A method of processing finely divided reactive particulates (R.sub.Particulate) and forming a product comprising: providing a composite material comprising finely divided reactive particulates (R.sub.Particulate) dispersed in a protective matrix; at least partially exposing the finely divided reactive particulates (R.sub.Particulate); and forming the product.

A molten salt electrolyzer having a metal collection chamber, an electrolysis chamber, and two or more electrolytic cell units positioned in the electrolysis chamber. Each electrolytic cell unit has a cathode having an inner space in a prism form; at least one bipolar electrode in a rectangular cylinder form and disposed in the cathode inner space; and an anode in a prism form and disposed in an inner space of the bipolar electrode. At least part of individual planes forming an outer side of the bipolar electrode closest to the cathode faces a plane forming the prism-form inner space of the cathode. At least part of individual planes forming the inner side of the bipolar electrode closest to the anode faces a plane forming the prism of the anode. At least one plane of the cathode constitutes one plane of a cathode of another electrolytic cell unit.

Process for producing a titanium alloy material, such as a titanium aluminum alloy, are provided. The process includes reduction of TiCl.sub.4), which includes a titanium ion (Ti.sup.4+), through intermediate ionic states (e.g., Ti.sup.3+) to Ti.sup.2+, which may then undergo a disproportionation reaction to form the titanium aluminum alloy.

Processes are provided for producing a titanium alloy material, such as TiAl alloys. In one embodiment, the process includes: heating an input mixture to a preheat temperature with the input mixture including aluminum, optionally, AlCl.sub.3, and, optionally ally, one or more alloying element halide; introducing TiCl.sub.4 to the input mixture at the first reaction temperature such that substantially all of the Ti.sup.4+ in the TiCl.sub.4 is reduced to Ti.sup.3+; thereafter, heating to a second reaction temperature such that substantially all of the Ti.sup.3+ is reduced to Ti.sup.2+ to form an intermediate mixture (e.g., a Ti.sup.2+ salt); and introducing the intermediate mixture into a reaction chamber at a disproportionation temperature reaction to form the titanium alloy material from the Ti.sup.2+ via a disproportionation reaction.

Process for producing a titanium alloy material, such as a titanium aluminum alloy, are provided. The process includes reduction of TiCl.sub.4, which includes a titanium ion (Ti.sup.4+), through intermediate ionic states (e.g., Ti.sup.3+) to Ti.sup.2+, which may then undergo a disproportionation reaction to form the titanium aluminum alloy.