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Ti-6Al-4V (TC4)

The most widely used titanium alloy in 3D printing, balancing strength, corrosion resistance, and biocompatibility for aerospace and medical use.

Ti-6Al-4V (TC4) is the most widely used titanium alloy for additive manufacturing, offering an exceptional combination of strength, corrosion resistance, and biocompatibility. It performs reliably in structural, aerospace, and medical environments due to its high fatigue strength and low density.

Using titanium 3D printing, TC4 enables production of complex, lightweight components including aerospace brackets, orthopedic implants, and high-performance mechanical parts. Additive manufacturing improves material efficiency, customization, and performance consistency in critical applications.

Ti-6Al-4V Similar Grades Table

Country/Region	Standard	Grade or Designation
USA	ASTM	Grade 5
USA	UNS	R56400
China	GB	TC4
Russia	GOST	BT6

Ti-6Al-4V Comprehensive Properties Table

Category	Property	Value
Physical Properties	Density	4.43 g/cm³
	Melting Range	1604–1660°C
	Thermal Conductivity (20°C)	6.7 W/(m·K)
	Thermal Expansion (20–500°C)	8.6 µm/(m·K)
Chemical Composition (%)	Titanium (Ti)	Balance
	Aluminum (Al)	5.5–6.75
	Vanadium (V)	3.5–4.5
	Oxygen (O)	≤0.20
	Iron (Fe)	≤0.30
Mechanical Properties	Tensile Strength	≥950 MPa
	Yield Strength (0.2%)	≥880 MPa
	Elongation at Break	≥10%
	Modulus of Elasticity	110 GPa
	Hardness (HRC)	32–36

3D Printing Technology of Ti-6Al-4V (TC4)

TC4 is compatible with Selective Laser Melting (SLM), Direct Metal Laser Sintering (DMLS), and Electron Beam Melting (EBM), making it one of the most accessible titanium alloys for high-performance 3D printed components.

Applicable Process Table

Technology	Precision	Surface Quality	Mechanical Properties	Application Suitability
SLM	±0.05–0.2 mm	Excellent	Excellent	Aerospace, Medical
DMLS	±0.05–0.2 mm	Very Good	Excellent	Consumer, Precision Parts
EBM	±0.1–0.3 mm	Good	Very Good	Large Aerospace and Industrial

Ti-6Al-4V 3D Printing Process Selection Principles

For high-precision aerospace or medical components with complex geometries and Ra 5–10 µm surface finishes, SLM is ideal for its dimensional accuracy and mechanical reliability.

DMLS is suitable for prototyping and high-volume functional parts that require strong fatigue performance and good machinability.

EBM is preferred for thicker components with good mechanical robustness and faster build rates, used in aircraft structural components or heavy-duty tools.

Ti-6Al-4V 3D Printing Key Challenges and Solutions

Residual stresses caused by thermal cycling are mitigated through robust support structures and Hot Isostatic Pressing (HIP), typically conducted at 920–950°C and 100–150 MPa to improve fatigue performance.

Porosity impacts strength and fatigue life. Laser parameter optimization (250–400 W, 600–1000 mm/s scan speed) and HIP post-processing increase part density above 99.9%.

Surface roughness (Ra 8–15 µm) impacts medical applications and mechanical contact surfaces. CNC machining or electropolishing improves surface finish to Ra 0.4–1.0 µm.

Powder must be protected from oxidation—storage and printing require oxygen <200 ppm and RH <5% to prevent embrittlement.

Industry Application Scenarios and Cases

Ti-6Al-4V is widely used in:

Aerospace: Brackets, hinges, internal supports, and airframe components.
Medical: Orthopedic implants, bone plates, and surgical instruments.
Consumer & Industrial: Lightweight structural parts, robotics, and sporting equipment.

A recent aerospace application using SLM-produced TC4 brackets achieved a 30% reduction in weight and a 20% increase in fatigue life over forged components, enhancing fuel efficiency and part longevity.