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A new REactive spray FORming (REFORM) process is being developed for the production of titanium aluminides. The REFORM process is potentially capable of synthesizing and forming these materials in a single unit operation. Aluminum powders and TiCl4 vapour have been fed into the tail flame of a d.c. plasma torch which operated on either argon or argon/hydrogen plasmas. The resulting high temperature reaction produced TiAl and Ti3Al intermetallics which were either collected on a cold substrate in a standard plasma spraying operation or quenched and collected as powder. Results of early experiments have produced materials containing up to 40% Ti …