Ti-5Al-2.5Sn (Grade 6)
Ti-5Al-2.5Sn (Grade 6) is a near-alpha titanium alloy offering excellent creep resistance, moderate strength, and high weldability. It performs well in elevated temperature environments up to 500°C and is commonly used in aerospace, industrial, and marine applications requiring thermal stability and corrosion resistance.
Using titanium 3D printing technologies, Ti-5Al-2.5Sn enables the efficient production of lightweight, high-integrity components like ducts, structural supports, and aerospace tubing. Additive manufacturing improves design flexibility and material utilization while reducing machining and assembly costs.
Ti-5Al-2.5Sn Similar Grades Table
Country/Region | Standard | Grade or Designation |
|---|---|---|
USA | ASTM | Grade 6 |
USA | UNS | R54520 |
China | GB | TA7 |
Russia | GOST | VT20 |
Ti-5Al-2.5Sn Comprehensive Properties Table
Category | Property | Value |
|---|---|---|
Physical Properties | Density | 4.48 g/cm³ |
Melting Range | 1630–1680°C | |
Thermal Conductivity (at 20°C) | 6.5 W/(m·K) | |
Thermal Expansion (20–500°C) | 8.8 µm/(m·K) | |
Chemical Composition (%) | Titanium (Ti) | Balance |
Aluminum (Al) | 4.5–6.0 | |
Tin (Sn) | 2.0–3.0 | |
Iron (Fe) | ≤0.25 | |
Oxygen (O) | ≤0.20 | |
Mechanical Properties | Tensile Strength | ≥860 MPa |
Yield Strength (0.2%) | ≥795 MPa | |
Elongation at Break | ≥10% | |
Modulus of Elasticity | 110 GPa | |
Hardness (HRC) | 30–35 |
3D Printing Technology of Ti-5Al-2.5Sn
This alloy is compatible with key metal additive manufacturing technologies including Selective Laser Melting (SLM), Electron Beam Melting (EBM), and Direct Metal Laser Sintering (DMLS). These processes support complex geometries and deliver parts with excellent mechanical and corrosion-resistant properties.
Applicable Process Table
Technology | Precision | Surface Quality | Mechanical Properties | Application Suitability |
|---|---|---|---|---|
SLM | ±0.05–0.2 mm | Excellent | Excellent | Aerospace, Heat-Resistant Parts |
DMLS | ±0.05–0.2 mm | Very Good | Excellent | Aerospace Tubing, Marine Parts |
EBM | ±0.1–0.3 mm | Good | Very Good | Large-Scale Structural Parts |
Ti-5Al-2.5Sn 3D Printing Process Selection Principles
For parts demanding dimensional accuracy (±0.05–0.2 mm), superior weldability, and thermal resistance, Selective Laser Melting (SLM) is the ideal choice for aerospace tubing and structural airframe parts.
Direct Metal Laser Sintering (DMLS) offers similar precision and is effective for lightweight marine parts, structural supports, and heat-resistant hardware with moderate complexity.
For large aerospace structures with moderate precision (±0.1–0.3 mm) and strong thermal performance, Electron Beam Melting (EBM) is best suited due to its high build rates and mechanical consistency.
Ti-5Al-2.5Sn 3D Printing Key Challenges and Solutions
Residual stress is a common issue during 3D printing of near-alpha titanium alloys. Implementing support structures and Hot Isostatic Pressing (HIP) at 920–950°C and pressures of 100–150 MPa relieves stress and improves part stability.
Porosity, especially at scan overlaps, can be reduced with optimized laser parameters—power around 200–350 W, scan speeds between 600–1000 mm/s—and HIP, achieving >99.8% part density.
Surface roughness, typically Ra 8–15 µm, impacts flow and fatigue performance. Post-processing using CNC machining or electropolishing achieves Ra 0.4–1.2 µm, meeting aerospace surface specs.
To prevent contamination, powder handling must be conducted in oxygen- and moisture-controlled environments (oxygen < 200 ppm, humidity < 5% RH).
Industry Application Scenarios and Cases
Ti-5Al-2.5Sn is widely used across multiple high-performance industries:
Aerospace: Hydraulic and pneumatic tubing, fuselage reinforcements, and heat shields.
Marine: Corrosion-resistant fasteners and structural panels for naval vessels.
Industrial Equipment: Heat exchanger shells and high-temperature supports.
In one aerospace case, SLM-produced tubing from Ti-5Al-2.5Sn achieved weight reductions of 20% and extended service life in thermal environments above 400°C, replacing heavier stainless steel solutions.
FAQs
What are the main advantages of Ti-5Al-2.5Sn (Grade 6) in additive manufacturing?
Which 3D printing technologies work best with Ti-5Al-2.5Sn components?
How does Ti-5Al-2.5Sn compare with other titanium alloys for aerospace use?
What challenges arise when printing Ti-5Al-2.5Sn, and how can they be mitigated?
What post-processing methods improve Ti-5Al-2.5Sn surface finish and fatigue strength?
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