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Ti-6Al-4V (Grade 5)

High-strength titanium alloy is widely used in 3D printing for aerospace, medical, and industrial applications requiring toughness and corrosion resistance.

Ti-6Al-4V (Grade 5) is the most widely used titanium alloy in additive manufacturing due to its excellent combination of strength, corrosion resistance, and lightweight properties. It performs reliably in aerospace, medical, and industrial environments requiring long-term durability and fatigue resistance.

Using titanium 3D printing, Ti-6Al-4V enables efficient production of high-performance parts such as aircraft brackets, orthopedic implants, and lightweight structural components, offering both precision and mechanical integrity.

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
	Iron (Fe)	≤0.30
	Oxygen (O)	≤0.20
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

Ti-6Al-4V is compatible with Selective Laser Melting (SLM), Direct Metal Laser Sintering (DMLS), and Electron Beam Melting (EBM), all of which produce high-quality, load-bearing parts for aerospace, medical, and industrial use.

Applicable Process Table

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

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

SLM is ideal for precision parts requiring tight tolerances (±0.05–0.2 mm), such as aerospace brackets and surgical tools.

DMLS is optimal for producing functional prototypes, complex geometries, and medical-grade parts with strong mechanical performance and fine detail.

EBM is best for large structural components, providing excellent microstructural control and high build rates for thermally demanding applications.

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

Residual stress and distortion can occur due to thermal gradients. These are mitigated through optimized support structures and Hot Isostatic Pressing (HIP) at 920–950°C and 100–150 MPa to improve fatigue strength and eliminate internal voids.

Porosity is reduced with tuned laser parameters (250–400 W, 600–1000 mm/s scan speed), followed by HIP, resulting in part density exceeding 99.9%.

Surface roughness (Ra 8–15 µm) affects fatigue and wear. CNC machining and electropolishing refine surfaces to Ra 0.4–1.0 µm, meeting aerospace and medical requirements.

Environmental control is critical to prevent oxygen pickup—powder must be processed in conditions with O₂ < 200 ppm and RH < 5%.

Industry Application Scenarios and Cases

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

Aerospace: Brackets, frames, ducting systems, and satellite parts.
Medical: Hip stems, trauma plates, dental abutments, and orthopedic implants.
Industrial: Tooling, valves, and corrosion-resistant structural components.

In a recent aerospace application, SLM-built Ti-6Al-4V brackets achieved 25% weight savings and 30% improvement in fatigue performance compared to machined alternatives, accelerating certification and reducing cost.