Titanium Ti6Al4V ELI Powder
Titanium Ti6Al4V ELI powder has carved a niche enabling high-performance additively manufactured parts across aerospace, medical, automotive, and specialty applications. Its tailored composition minimizes detrimental impurities while retaining the strength, fracture resistance and biocompatibility benefits of titanium alloy.
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Table of Contents
Overview
Titanium Ti6Al4V ELI powder is a high-performance titanium alloy widely used in 3D printing, additive manufacturing, and metal injection molding applications across aerospace, medical, automotive, and other demanding industries.
Ti6Al4V ELI refers to an “extra low interstitial” variant of Grade 5 titanium that contains lower amounts of oxygen, nitrogen, carbon, and iron compared to standard Ti6Al4V. This results in improved ductility, fracture toughness, fatigue strength, and high-temperature creep resistance.
As a metal powder feedstock, Ti6Al4V ELI enables complex geometries and lightweight, high-strength structures to be fabricated using powder bed fusion and directed energy deposition 3D printing. Parts can be produced with fine surface finishes and mechanical properties comparable to traditionally forged or cast Ti6Al4V components.
Below we explore Ti6Al4V ELI powder in more detail including composition, properties, specifications, pricing, applications, and comparisons to alternatives like CP titanium and stainless steel powders.
Composition
Titanium Ti6Al4V ELI powder has the following nominal composition:
| Element | Weight % |
|---|---|
| Aluminum (Al) | 5.5 – 6.75 |
| Vanadium (V) | 3.5 – 4.5 |
| Oxygen (O) | <= 0.13 |
| Nitrogen (N) | <= 0.05 |
| Carbon (C) | <= 0.08 |
| Hydrogen (H) | <= 0.0125 |
| Iron (Fe) | <= 0.25 |
| Titanium (Ti) | Balance |
The key alloying elements – aluminum and vanadium – serve to strengthen the titanium matrix through solid solution strengthening and precipitation hardening mechanisms upon heat treatment.
The ELI variant ensures strict control of interstitial impurities like O, N, C, and Fe to minimize detrimental effects on ductility and fracture resistance at high temperatures.
Properties
Some key properties of Ti6Al4V ELI alloy in its pre-alloyed powder form are highlighted below:
Mechanical Properties
| Property | Value |
|---|---|
| Tensile Strength | ≥ 895 MPa (130 ksi) |
| Yield Strength | ≥ 825 MPa (120 ksi) |
| Elongation | ≥ 10% |
| Hardness | 334 HV (32 HRC) |
Physical Properties
| Property | Value |
|---|---|
| Density | 4.43 g/cm3 |
| Melting Point | 1604 – 1660°C (2920 – 3020°F) |
| Thermal Conductivity | 6.7 W/m·K |
| Electrical Resistivity | 170 – 190 μΩ·cm |
Printing Properties
| Property | Value |
|---|---|
| Printing Process | Laser – PBF, EBM<br>Arc – DED |
| Particle Size | 15 – 45 μm |
| Apparent Density | ≥ 2.7 g/cm3 |
| Flow Rate | ≥ 30 s/50 g |
Service Conditions
| Property | Value |
|---|---|
| Max Service Temperature | 400 – 500°C (750 – 930°F) |
| Corrosion Resistance | Excellent overall |
| Weldability | Excellent |
| Heat Treatability | Solution treat + age |
Applications
The unique properties of titanium Ti6Al4V ELI alloy powder make it suitable for:
Aerospace
- Structural brackets, housings, engine components
- Airframe and helicopter parts, wings, fuselages
- Spacecraft propulsion systems, thrust nozzles
Medical & Dental
- Orthopedic implants – hip, knee, spinal fixation
- Dental implants, crowns, bridges, abutments
Automotive
- Connecting rods, valves, turbocharger wheels
- Motor sports gear – engine blocks, brake calipers
Chemical
- Reactor vessels, heat exchangers, pipes, tanks
- Pumps, valves, reaction towers, scrubbers
Other
- Sporting goods – bicycles, golf clubs, frames
- Defense – armored vehicles, body armor plates
- Energy – wellhead components, fluid end parts
The following table summarizes some typical applications of Ti6Al4V ELI components fabricated using metal AM techniques:
| Industry | Applications | Benefits |
|---|---|---|
| Aerospace | Turbine blades, engine brackets | Weight savings, performance |
| Biomedical | Hip, cranial implants | Biocompatibility, osseointegration |
| Automotive | Connecting rods, brake calipers | Lightweighting, custom geometries |
| Energy | Fluid end parts, wellhead components | Corrosion resistance, reduced inventory |
Additive manufacturing using Ti6Al4V ELI powder is valued for enabling:
- Weight reduction – lighter vs. steel, nickel alloys
- Part consolidation – fewer fasteners, welds needed
- Customized geometries – topology optimization
- Reduced waste – minimal raw material use
- Just-in-time production – reduced lead times
Specifications
Titanium Ti6Al4V ELI powder products are available adhering to the following specifications:
| Standard | Type/Grade Designation | Composition Limits |
|---|---|---|
| ASTM F2924 | Ti6Al4V ELI | O, Fe, N, C limits per ASTM F136 |
| ASTM F3001 | Grade 23 ELI | Al, V, O, N, C ranges |
| ISO 23377 | Ti6Al4V ELI | O, N, C, H limits |
Popular size grades conforming to ASTM B214 are:
| Grade | Particle Size (μm) | Oxygen Content (%) |
|---|---|---|
| -100+325 mesh | 45 – 149 | 0.08 – 0.13 |
| -200 mesh | ≤ 75 | ≤ 0.14 |
| -325 mesh | ≤ 45 | ≤ 0.12 |
Finer particle sizes down to 10 μm may be available for high-resolution printing.
Suppliers & Pricing
Below is a table of several leading global suppliers of Ti6Al4V ELI powder and the typical pricing in USD per kilogram:
| Supplier | Pricing ($/kg) |
|---|---|
| AP&C | $275 – $325 |
| Carpenter Additive | $250 – $300 |
| GKN Hoeganaes | $290 – $380 |
| Praxair | $310 – $350 |
| Sandvik Osprey | $280 – $335 |
Average pricing as of 2024 is around $300/kg for Ti6Al4V ELI powder meeting ASTM F2924 or similar specifications tailored for AM usage.
As a premium grade, ELI powders command nearly a 100% price premium over standard Ti6Al4V powders (~$150-$200/kg).
Factors influencing pricing include order volume, particle size distribution, interstitials content, morphology, apparent density, and flow characteristics.
Comparisons
Ti6Al4V ELI vs. Ti6Al4V
- Extra low interstitial (ELI) variants are purer, more ductile, tougher and consistent.
- ELI grades have lower oxygen, nitrogen, carbon and iron levels.
- Ti6Al4V ELI costs about 100% more than Ti6Al4V powder.
- Properties are very similar otherwise – Ti6Al4V offers adequate performance for most uses.
- Industries like aerospace mandate ELI grades for critical rotating parts in jet engines or airframes.
Ti6Al4V ELI vs. CP Titanium Grade 2
- Ti6Al4V ELI has higher strength – over 50% increase in tensile and yield strength.
- It retains the biocompatibility and corrosion resistance of CP titanium.
- Alloying additions make Ti6Al4V less formable but heat treatable for strengthening.
- CP Ti Grade 2 has lower hardness and wears faster in service but is less expensive.
- Both are popular materials for orthopedic implants like hip and knee replacements.
Ti6Al4V ELI vs. Stainless Steel 316L
- Ti6Al4V ELI has lower density – nearly half that of 316L steel – so is lighter in weight.
- It offers 2-3X higher specific strength thanks to the low density.
- Steel is easier/cheaper to machine but affected by corrosion issues
Ti6Al4V ELI vs. Inconel 718
- Inconel 718 has over 50% higher tensile strength than annealed Ti6Al4V ELI alloy.
- However, Inconel is nearly twice as dense, negating much of the strength advantage.
- Ti6Al4V ELI retains strength better at elevated temperatures – up to 300°C.
- Inconel 718 offers oxidation resistance up to 700°C but is much harder to machine.
- Both nickel alloy and titanium powder are widely used in aerospace engines and airframe components.
Ti6Al4V ELI vs. Cobalt Chrome (CoCr)
- As a biocompatible metal alloy, CoCr competes with Ti6Al4V ELI in medical implants like knee and hip replacements.
- Ti6Al4V ELI has a more ideal combination of strength, ductility and fracture toughness.
- It promotes better osseointegration and bone in-growth over time.
- CoCr alloy can suffer from metal ion leaching issues leading to inflammation risks.
- Ti6Al4V ELI is preferred for orthopedic load bearing implants while CoCr sees more use in dental applications.
Pros and Cons
Advantages of Titanium Ti6Al4V ELI:
- Excellent strength-to-weight ratio
- Low density translates to lightweight parts
- Retains properties at elevated temperatures
- Resistant to corrosion in harsh environments
- Bioinert – avoids rejection by human body tissues
- Powder feedstock allows complex, optimized shapes using AM
- Wide range of applications across industries
Disadvantages:
- More expensive than steel or aluminum powders
- Lower tensile and fatigue strength than nickel alloys
- Lower hardness and wear resistance necessitates coatings
- Reactivity with oxygen at high temperatures
- Less thermal and electrical conductivity vs. other metals
Conclusion
Titanium Ti6Al4V ELI powder has carved a niche enabling high-performance additively manufactured parts across aerospace, medical, automotive, and specialty applications.
Its tailored composition minimizes detrimental impurities while retaining the strength, fracture resistance and biocompatibility benefits of titanium alloy.
Part design freedom, rapid prototyping, waste reduction, and inventory savings expand markets for Ti6Al4V ELI further.
As metal AM matures, widespread adoption beyond aerospace into implants, motorsports components, fluid handling hardware can be expected – subject to casting off cost barriers relative to incumbent technologies like forging and machining.
FAQs
Q: What does the ELI designation mean for Ti6Al4V powder?
A: ELI stands for “extra low interstitial” reflecting tighter control of O, N, C, H impurities to enhance ductility and fracture toughness.
Q: Is Ti6Al4V ELI approved for medical or aerospace use?
A: Yes, leading standards bodies like ASTM F2924, ISO 23377 recognize Ti6Al4V ELI compositions – clearance for human implant or flight critical applications.
Q: Does Ti6Al4V ELI powder require hot isostatic pressing (HIP) post-processing?
A: Not necessarily – today’s AM machines can deliver >99% dense Ti6Al4V structures rivaling cast/wrought properties without HIP.
Q: Can you heat treat & age harden 3D printed Ti6Al4V ELI parts?
A: Yes, solution treatment followed by aging allows precipitation hardening to 60+ HRC achieving 1,200+ MPa ultimate tensile strength.
Q: How does Ti6Al4V ELI powder reuse affect properties of printed parts?
A: Reused powder can see increased oxygen pickup degrading ductility – refreshed powder is advised for critical applications.
Q: Does Ti6Al4V ELI welding require inert gas shielding?
A: Yes, high purity argon shielding prevents discoloration and embrittlement; helium mixes also used.
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