Titanium Aluminides are of increasing interest in aerospace applications as they have excellent strength-to-weight properties. However, they are difficult to process as they are relatively brittle. In this study, powder metallurgy routes involving reactive sintering and hot extrusion have been chosen for the production of titanium aluminides from elemental powders as they permit control of compositional gradients, something which cast ingot processing routes do not. Green billets of titanium-rich and aluminium-rich compositions were fabricated by pressing and subsequently either sintered or hot extruded. Various isothermal sintering heat treatments were compared, heating compacted solids slowly at temperatures ranging from 500-600°C in argon, resulting in the formation of intermetallic titanium aluminide Al3Ti along with large amounts of porosity, whereas rapid heat treatments of compacted solids produced other intermetallics TiAl and Ti3Al at temperatures of 800-1000°C. Hot extrusion in air at temperatures ranging from 400-450°C, rapidly produced the titanium aluminides TiAl and Ti3Al in an extremely fast and highly exothermic SHS (Self-propagating high temperature synthesis) reaction, accompanied by the formation of an outer oxide layer around the extrude exterior. It was also found that hot extrusion in argon suppressed the SHS reaction under these processing conditions. Therefore the presence of oxygen must be required for the reaction to proceed. Materials characterisation by X-Ray analysis, differential thermal analysis, scanning electron microscopy and image analysis was conducted. Finite element analysis of the hot extrusion process indicated that hot extrusion alone is not sufficient to raise the temperature of the extrude to the higher temperatures at which TiAl and Ti3Al form. Extra heat is required to initiate the exothermic SHS reaction, confirming the hypothesis that the oxide formation is necessary to trigger the SHS reaction, which travels down the length of the extrude as the elemental metals are consumed. Calculations have been made to attempt to ascertain the minimum amount of oxidation required to initiate the reaction.