Two processes are proposed to produce Ti powder directly from TiCl4 gas using
molten magnesium as reductant. TiCl4 gas injection into a liquid Mg layer
through the molten chloride salts could produce the Ti powder of 1 to 10 mm in
diameter. Neither the operation temperature nor the salt composition affected
the powder morphology. When TiCl4 was dissolved once in the molten salt as
Ti2+, and when Mg successively reduced this Ti2+, the Ti morphology varied from
the needle-like to the round shape by raising the reduction temperature.