The production process begins with rutile combined with coke or tar and chlorine gas, heated to yield titanium tetrachloride (TiCl4). This compound undergoes chemical conversion into a sponge-like material, subsequently melted into ingot form using either Vacuum Arc Remelting (VAR) or a cold hearth furnace. Alloyed grades include added alloying agents during compaction. The resulting ingots are processed into various mill products using standard metalworking equipment.

Titanium's metallurgical characteristics make it indispensable across diverse sectors, including aerospace, defense, industrial and chemical processing, medical applications, naval and marine industries, sporting equipment, and consumer goods. Initially pivotal in military aerospace for its superior structural qualities and strength-to-density ratio, titanium's density ranges from 0.160 lb/in³ to 0.175 lb/in³, varying by grade.

Key to titanium's appeal is its natural formation of a ceramic-like oxide film upon exposure to oxygen, imparting exceptional corrosion and erosion resistance. This self-healing oxide layer mitigates scratches when in contact with oxygen.

Biocompatible, titanium finds extensive use in medical implants such as hip and knee replacements, pacemaker cases, dental implants, and craniofacial plates. Its nonmagnetic properties, ability to maintain strength at high temperatures, high melting point, excellent strength-to-weight ratio, corrosion resistance in diverse oxidizing environments (including brackish and saltwater), and low modulus of elasticity further underscore its versatility.

In conclusion, titanium's blend of durability, resilience, and adaptability cements its status as an essential material across various industries, promising continued innovation and application in the future.