Titanium 3D Printing Powder

Overview

Titanium is a strong, lightweight structural metal gaining extensive use in additive manufacturing across the aerospace, medical, automotive and industrial sectors. Titanium alloy powders like Ti-6Al-4V enable complex parts to be 3D printed delivering high strength along with corrosion resistance and biocompatibility.

Selective laser melting (SLM) and electron beam melting (EBM) can process fine titanium powder into fully dense components with intricate designs not feasible through machining or casting. This guide covers Ti alloy compositions, properties data, applications, printer parameters and suppliers to leverage benefits with metal 3D printing.

Composition of Titanium Printing Powders

Titanium alloys comprise primarily titanium with other alloying elements like aluminum, vanadium, iron, molybdenum and more to enhance specific properties. Most common titanium grades for AM include:

• Ti-6Al-4V (Grade 5) is the most popular titanium alloy, with its strength coming from +Al stabilizing and +V precipitation hardening. An extra low interstitial (ELI) variant has high ductility.
• Ti 6242 alloy replaces some Vanadium to make it more suitable for biocompatible orthopedic implants requiring osseointegration.
• Trace elements like iron, oxygen, nitrogen and carbon are minimized as they adversely impact mechanical properties if present beyond specified limits.

Properties of Metal Titanium Printing Powders

Key material property attributes which make titanium alloys attractive for aircraft and medical products include:

• High strength relative to low density (half of steel) makes titanium components lighter. Strength surpasses common aluminum alloys while avoiding corrosion issues.
• Ductile enough for cold forming. Extra low interstitial variants like Ti64 ELI further boost elongation.
• Melting exceeds 1600°C. Maintains properties at 400-500°C nicely.
• Thermal and electrical conductivities are quite low to avoid sparks and isolate heat.

Applications of Metal 3D Printed Titanium Parts

Aerospace

• Structural airframe brackets, ribs, impellers and fittings
• Lightweighted turbocharger housings and heat exchangers
• Conformal cooling channels integrated into jet engine turbine sections
• Customized UAV/drone frames conforming to components

Medical and Dental

• Orthopedic knee, hip, spine and jaw implants like acetabular cups
• Dental abutments for crowns and bridges
• Customized cranial reconstruction plates specific to patient anatomy

Automotive

• Motor housing brackets and suspension components
• Conformal close-contour cooling integrated into injection molds
• Lightweight brake disc rotors with intricate air flow geometries

Process Parameters for 3D Printing Titanium

Key parameters when using titanium powder material in powder bed fusion processes:

LPBF Settings

EBM Settings

LPBF requires support structures while EBM build metal without assistance. ≥99% density is achieved after stress relief and hot isostatic pressing. Minimum wall thicknesses reach 100-150 microns typically.

Suppliers of Titanium Printing Powders

Leading metal manufacturing companies have certified titanium powders for additive processes:

Cost of Titanium Printing Powders

As an advanced lightweight alloy for high performance applications, titanium powder commands a premium:

• Material prices range from $200 to $500 per kg
• Custom alloys with tighter particle sizes and high purity further increase costs
• Recycled powder is cheaper assuming good flowability

Post Processing for Titanium 3D Printed Parts

After printing, titanium components undergo:

Support Removal – Carefully separate supports via EDM cutting where accessible, snap off smaller features

Stress Relieving – Gently heat treat entire build plate to 650°C for 2 hours in argon reducing residual stresses

Hot Isostatic Pressing – HIP process at 920°C and 100 MPa for 3 hours to close internal voids >99% density

Solution Treatment – Soak at 705°C for 1 hour then air/water quench to develop desired microstructure

Machining – CNC mill critical mating surfaces to meet dimensional tolerance needs

Blast + Acid Etch – Alumina shot peen followed by acid etching to clean surfaces

Quality Testing – Confirm chemistry, microstructure, layer-by-layer quality and mechanical properties meet specifications

Standards for Titanium 3D Printing

Future Outlook for Powder Bed Printing Using Titanium

While aerospace drives 70% of demand currently thanks to significant part consolidation and weight saving benefits, titanium AM adoption will accelerate across automotive, sporting goods and more consumer sectors as costs decline. More Ti printed applications include:

Aerospace – Larger and fully printed primary structures like turbine blades and future passenger cabin sections, leveraging strengths in design complexity, part assembly consolidation and corrosion resistance.