The present invention is generally directed towards a method for producing
a solid metallic composition by reacting a gaseous metal halide with a
reducing agent are described. In one embodiment, the method includes
reacting a gaseous metal halide with a reducing agent in a manner
effective to form a nonsolid reaction product, wherein the metal halide
has the formula MX.sub.i, in which M is a metal selected from a
transition metal of the periodic table, aluminum, silicon, boron, and
combinations thereof, X is a halogen, i is greater than 0, and the
reducing agent is a gaseous reducing agent selected from hydrogen and a
compound that releases hydrogen, and combinations thereof; and
solidifying the reaction product, thereby forming a metallic composition
comprising M that is substantially free from halides. The invention may
be used to produce high-purity metallic compositions, particularly
titanium particles and alloys thereof for use in powder metallurgy
applications.