Titanium Ti-6Al-4V (Grade 5)
The most widely used titanium alloy in additive manufacturing. Ti-6Al-4V combines exceptional strength-to-weight ratio with corrosion resistance, making it the standard for aerospace structural components and medical implants.
About Titanium Ti-6Al-4V (Grade 5)
Ti-6Al-4V (Grade 5) is an alpha-beta titanium alloy that accounts for more than 50% of all titanium usage globally. In additive manufacturing, it is the dominant metal alloy for applications where weight savings, mechanical performance, and biocompatibility are critical.
The alloy delivers tensile strengths above 1,000 MPa in as-built condition via LPBF, with elongation values of 8–14% depending on build orientation and heat treatment. Hot Isostatic Pressing (HIP) is commonly applied to close internal porosity and improve fatigue life — essential for flight-critical aerospace parts.
Ti-6Al-4V is approved under multiple aerospace and medical standards including AMS 4999, ASTM F2924, and ISO 5832-3. Its biocompatibility makes it the material of choice for orthopaedic implants, spinal cages, and dental prosthetics.
Key challenges include reactive powder handling (requiring inert atmosphere processing), support structure removal in complex geometries, and relatively high material cost compared to steel alloys.
Typical Applications
- Aerospace structural brackets and fittings
- Turbine blades and engine components
- Orthopaedic implants (hip, knee, spinal)
- Dental crowns and bridges
- Motorsport lightweight components
- Marine and chemical processing equipment
Engineering Considerations
- Requires inert atmosphere (argon) during printing to prevent oxidation
- Support structures are mandatory for overhangs >45° and add post-processing time
- HIP treatment recommended for fatigue-critical applications
- Powder is classified as a fire/explosion hazard — specialist handling required
- Machining after printing requires carbide or ceramic tooling due to work hardening