The formation of titanium aluminides from the elemental powders has been investigated. A traditional powder metallurgy route of compaction (by cold isostatic pressing, hot pressing or hot extrusion) followed by heat treatment was compared with the novel technique of hot extrusion reaction synthesis (HERS). The products from these different production methods were characterised by x-ray diffraction and microscopy (light and scanning electron). The intermetallic compound formed under most processing conditions was TiAl3. Only when there was a rapid increase in temperature to high temperatures, as found in induction heating of compacts or in HERS, were the compounds Ti3Al and TiAl formed.