The technology of producing small-size batches of mechanically alloyed filler metals from elemental metal powders or hydrides by the solid-state synthesis in a high-energy ball mill was developed to cut the production costs (associated with the manufacturing of small batches) by 40-50%. Some of these alloys such as TiBraze375 (Ti-37.5Zr-15Cu10Ni), TiBraze260 (Ti-26Zr-14Cu- 14Ni-0.5Mo), and TiBraze 15-25 (Ti-15Cu-25Ni-0.5Mo) have been successfully tested and used by the aerospace industry. These mechanically alloyed filler metals are characterized by a low erosion of the base materials, a tensile strength of Ti-6Al-4V brazed joints in the range of 91-107 ksi (626-740 MPa) depending upon the brazing joint clearance and temperature, a shear strength of joints between 75-84 ksi (520-580 MPa), and by a relatively low brazing temperature in the range of 1562-1634F (850-890 deg C). The combined properties of these filler metals allow for effective brazing below the beta-transus temperature of most titanium-base alloys. Solid-state synthesis of Ti-Zr-Cu-Ni alloys was investigated by varying the time of high-energy ball milling. The products were studied via differential thermal analysis (DTA), energy-dispersive spectroscopy (EDS) analysis, and scanning electron microscopy. Clear evidence of solid-state reactions obtained in this study confirm that the resulting products are partially prealloyed and comprise Cu and Ni, which are dispersed throughout the Ti and Zr phases. Differential thermal analysis results displayed a decrease in the liquidus temperature as a result of this milling. The notable effect of milling is the induced exothermic effect prior to melting of mechanically alloyed brazing alloys.