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Titanium Grade 5 (Ti-6Al-4V)
Titanium Grade 5 (Ti-6Al-4V), often called the "workhorse" titanium alloy, is an alpha-beta titanium alloy containing 6% aluminum and 4% vanadium. It accounts for over 50% of all global titanium consumption and represents the most widely used titanium grade across aerospace, medical, marine, and high-performance industrial applications. Ti-6Al-4V delivers an exceptional strength-to-weight ratio — roughly 40% lighter than steel with comparable strength — combined with outstanding corrosion resistance, biocompatibility, and the ability to withstand temperatures up to approximately 400°C (750°F).
Mechanical Properties
- Density: 4.43 g/cm³
- Tensile Strength: 950 MPa
- Yield Strength: 880 MPa
- Elongation at Break: 14%
- Hardness: HRC ~36
- Modulus of Elasticity: 114 GPa
- Thermal Conductivity: 6.7 W/m·K
- Electrical Conductivity: ~0.7 % IACS
- Melting Point: 1660 °C
- Coefficient of Thermal Expansion: 8.6 × 10⁻⁶ /°C
Advantages
✔ Outstanding Strength-to-Weight Ratio — Approximately 40% lighter than steel with comparable tensile strength; critical for weight-sensitive aerospace and racing applications
✔ Exceptional Corrosion Resistance — Naturally forms a protective oxide layer; virtually immune to chloride-induced pitting, seawater corrosion, and most chemical environments
✔ Biocompatible & Medical-Grade — ISO 10993 / ASTM F67 compliant for implants; non-toxic and non-allergenic; widely used in orthopedic and dental implants
✔ High-Temperature Capability — Retains mechanical properties up to ~400°C; suitable for jet engine components, turbocharger parts, and thermal systems
✔ Low Modulus of Elasticity — More flexible than steel (114 GPa vs. 200 GPa); provides natural vibration damping in dynamic applications
Machining & Manufacturing
| Parameter | Specification | Notes |
| Cutting Speed | Carbide tooling: 40–100 SFM (12–30 m/min) | Low thermal conductivity and work hardening lead to lower speed than steel and aluminum |
| Feed Rate | Roughing: 0.05–0.15 mm/revFinishing: 0.02–0.08 mm/rev | Requires rigid machining setup |
| Tooling | Solid carbide / carbide inserts only; sharp tools with 5°–10° positive rake; TiAlN or dedicated titanium coatings | HSS is not applicable for formal production |
| Coolant | Spindle through-coolant (min. 70 bar) required; MQL is also available | Flood cooling cannot meet cooling demands; prioritize cooling at tool tip |
| Machining Difficulty | Difficult | Demands rigid equipment, high-grade tools and optimized cutting parameters |
Special Notes:
- Maintain constant tool engagement — interrupted cutting causes micro-cracking at the tool edge from thermal cycling
- Avoid dwelling or rubbing — titanium work-hardens rapidly under frictional heat
- Use large core-diameter end mills to minimize deflection/vibration
- Replace tools proactively before visible wear; titanium accelerates flank wear unpredictably
- Consider optimized tool paths (trochoidal milling) to reduce tool load and heat buildup
Common Applications
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