The method is suitable for the manufacture of flat or shaped titanium
aluminide articles and layered metal matrix composites such as
lightweight plates and sheets for aircraft and automotive applications,
thin cross-section vanes and blades, composite electrodes, heat-sinking
lightweight electronic substrates, bulletproof structures for vests,
partition walls and doors, as well as for sporting goods such as helmets,
golf clubs, sole plates, crown plates, etc. The method includes the
following steps: (a) forming a porous preform of the reactive powder
alloy or a porous multi-layer composite preform consisting of reactive
powder metals and alloys by consolidation using at least one method
selected from low-temperature loose sintering in vacuum, high-temperature
loose sintering in vacuum, low-pressure sintering in an inert gas, cold
pressing, direct powder rolling, isostatic or die pressing, and other
means of room temperature and warm temperature consolidation, and/or
combination thereof, to provide the density not less than 25% from the
theoretical density of said reactive alloy; (b) hot consolidating by hot
pressing said preform, hot rolling, hot isostatic pressing, or hot
extrusion to obtain the density of 98-100% from the theoretical density
of said reactive alloy; (c) additional sintering and/or annealing at the
temperature being at least 900.degree. C. to decrease the residual
porosity, control the microstructure, and improve the mechanical
properties, especially ductility and/or plasticity of the resulting metal
sheets or layered composites. The hot pressing is carried out at the
temperature ranging 950-1700.degree. C., preferably at 1250-1450.degree.
C., and at pressure ranging 50-350 kg/cm.sup.2. The HIP is carried out at
the temperature ranging 1250-1350.degree. C. and at pressure ranging
15000-40000 psi. The layered composite preform is manufactured by
individual loose sintering, one layer of the composite at a time, and
assembling them in the desired order. The composite consists of layers of
titanium and/or titanium hydride, Ti-6Al-4V alloy, .alpha.-titanium
aluminide alloy, .beta.-titanium aluminide alloy, and .gamma.-titanium
aluminide alloy in any combinations.