Intermetallic sheet materials that are difficult to process by conventional techniques can be processed using a method involving cold roll bonding and reaction annealing of elemental foils. This method was used to study the reactions that form at the roll bonded interface as a function of rolling strain using the Ti-Al system as the model. Titanium aluminides were successfully produced at the Ti/Al interface by cold roll bonding of elemental titanium and aluminum foils and subsequent two-stage reaction annealing. A certain threshold reduction in thickness is required in the first rolling pass to bond the elemental foils successfully. Differential scanning calorimetry (DSC) studies revealed that increased rolling strain increased the exothermicity of the reactions. Increasing the strain was found to accelerate the diffusion rate of the metallic elements, which could lead to a reduction in processing time. The thickness, morphology, and composition of the intermetallic compounds that formed at the Ti/Al interface were examined using light microscopy and scanning electron microscopy equipped with energy dispersive spectrometry. The phases formed were verified using x-ray diffraction.