It has long been a goal to produce Ti Alloy powder directly to eliminate the standard processing of melting sponge, alloying, producing a billet/ingot and then reducing to powder by one of several techniques. The batch Kroll process where reaction occurs at the reactor wall interface from TiCl4 vapor and molten magnesium, limits the potential to directly form alloys. Any batch processing has the limitation of alloy compositional control from batch to batch. A unique continuous processing approach permits the gaseous mixing of chloride precursors with metallothermic reduction that directly produces an alloy powder in a size that is useable for standard powder metallurgy. Discussion will include producing Ti-6Al-4V and other alloy powder.