Titanium tetrahalide (preferably titanium tetrachloride) is reduced to titanium metal particles by reaction with an alkali metal dispersed in a non-aqueous, organic ionic liquid. The dispersion is enhanced using high-shear mixing. By-product alkali metal chloride salt(s) is dissolved in the ionic liquid. Precipitated titanium metal powder is readily separated from the ionic liquid solution as a product. And the separated solution may be subjected to electrolysis to recover chlorine gas, electrodeposited alkali metal, and the ionic liquid. Other metal halides may be added with the titanium halide to form titanium-based alloys or other titanium based products.