Ticl4, alcl3, and vcl4 were coreduced simultaneously via a kroll- type magnesium reduction to form an alloy sponge as part of a research effort by the Bureau of Mines to produce titanium alloy powder. Reduction temperatures of 750 deg, 850 deg, and 950 deg c, a range of chloride feed rates from 34 to 152 lb/(ft2.H), and crucible diameters of 7 3/4 and 10 1/4 in were tested. Microprobe analyses using a 40-um-diam spot showed no effect on alloy microhomogeneity (distribution of al and V in the ti, considered critical as a powder property) owing to changes in process variables within these ranges. Statistical analysis of these data for alloy sponge indicated greater variation in the chemical composition (al and v) than that found in commercial ti-6al-4v plate or plasma rotating electrode process powder. Therefore, a one-step approach to powder, such as grinding the ti alloy sponge, would not produce a powder product of acceptable chemical homogeneity. An approach that homogenized the sponge, such as with a melting step, would produce an acceptable powder product with respect to chemical homogeneity.