Ti-6Al-2Sn-4Zr-2Mo Powder: The Ultimate Guide for 2025

Overview

Ti-6Al-2Sn-4Zr-2Mo powder (commonly referred to as Ti-6-2-4-2) is a high-performance titanium alloy known for its exceptional strength, high-temperature resistance, and superior oxidation resistance. This alloy is widely used in aerospace, automotive, and high-temperature structural applications, especially in jet engines, airframe components, and gas turbines.

This alloy consists of:
✔ 6% Aluminum (Al) – Strengthens the alloy and enhances oxidation resistance.
✔ 2% Tin (Sn) – Improves creep resistance and thermal stability.
✔ 4% Zirconium (Zr) – Enhances oxidation and corrosion resistance.
✔ 2% Molybdenum (Mo) – Improves high-temperature strength and creep resistance.
✔ Titanium (Ti) as the base element, providing lightweight yet strong material properties.

Key Properties

✔ Excellent high-temperature strength (up to 540°C), making it ideal for jet engines and turbine components
✔ Superior oxidation resistance, ensuring long-term performance in extreme environments
✔ Low density (~4.55 g/cm³), offering a high strength-to-weight ratio
✔ Good creep resistance, improving reliability in high-stress applications
✔ Optimized for additive manufacturing (AM), including Laser Powder Bed Fusion (LPBF) and Electron Beam Melting (EBM)

This guide will cover:

• Best Ti-6Al-2Sn-4Zr-2Mo powder for 3D printing
• How to choose the right Ti-6Al-2Sn-4Zr-2Mo powder
• Top suppliers of Ti-6Al-2Sn-4Zr-2Mo powder
• Properties and industrial applications
• Production methods and cost analysis
• Comparing gas-atomized vs. plasma-atomized Ti-6Al-2Sn-4Zr-2Mo powder

Best Ti-6Al-2Sn-4Zr-2Mo Powder for 3D Printing in 2025

Why Ti-6Al-2Sn-4Zr-2Mo Powder is Ideal for Additive Manufacturing?

• High oxidation resistance, making it perfect for turbine components and aerospace structures
• Superior mechanical properties, ensuring fatigue and creep resistance
• Excellent printability, reducing defects in LPBF and EBM processes
• Lightweight, high-strength structure, making it suitable for aviation and space applications

Key Factors for Selecting Ti-6Al-2Sn-4Zr-2Mo Powder for 3D Printing

• Spherical morphology for optimal powder flowability
• Controlled particle size distribution enhances printability and layer adhesion
• Low oxygen & impurity levels prevent oxidation defects
• Consistent mechanical properties post-processing

Comparison for Different 3D Printing Technologies

For high-performance 3D printing applications, Met3DP’s gas-atomized Ti-6Al-2Sn-4Zr-2Mo powder is the best choice. Learn more about Met3DP’s high-quality metal powders.

How to Choose the Right Ti-6Al-2Sn-4Zr-2Mo Powder

Selecting the best Ti-6Al-2Sn-4Zr-2Mo powder depends on several factors, including particle size distribution, atomization process, and application-specific requirements.

1. Particle Size Distribution (PSD)

• Fine powders (15-45µm) → Best for LPBF (Laser Powder Bed Fusion)
• Medium powders (45-105µm) → Suitable for EBM & Binder Jetting
• Coarse powders (50-150µm) → Used in DED (Direct Energy Deposition)

2. Powder Morphology

• Spherical Powder → Best for 3D printing and powder bed fusion technologies
• Irregular Powder → Suitable for Binder Jetting & Sintering

3. Atomization Process

• Gas-Atomized Powder → High purity, excellent flowability, best for 3D printing
• Plasma-Atomized Powder → Ultra-high purity, best for aerospace and high-performance applications

For high-precision 3D printing, Met3DP’s gas-atomized Ti-6Al-2Sn-4Zr-2Mo powder is the best choice. Contact Met3DP for more details.

Production Methods

The manufacturing process of Ti-6Al-2Sn-4Zr-2Mo powder plays a crucial role in determining its particle morphology, purity, and mechanical properties, which significantly impact its performance in additive manufacturing, aerospace applications, and high-temperature structural components.

Comparison of Production Methods

1. Gas Atomization (GA)

Process:

• Molten Ti-6Al-2Sn-4Zr-2Mo alloy is atomized into fine droplets using high-pressure inert gas (argon or nitrogen), which rapidly solidifies into spherical powder particles.

Advantages:
✔ Highly spherical morphology, improving flowability and printability
✔ Low oxygen content, reducing oxidation defects
✔ Excellent particle size distribution, ensuring consistent layer deposition in additive manufacturing

Best for: Laser Powder Bed Fusion (LPBF), Electron Beam Melting (EBM), and Direct Energy Deposition (DED)

2. Plasma Atomization (PA)

Process:

• Ti-6Al-2Sn-4Zr-2Mo wire is fed into a high-energy plasma torch, melting it into fine droplets that form highly spherical powder particles.

Advantages:
✔ Perfect spherical shape, ensuring superior flowability in powder bed fusion processes
✔ Ultra-high purity, making it ideal for aerospace and high-performance applications
✔ Minimal satellite particles, leading to superior print quality

Disadvantages:
✖ Higher production costs
✖ Limited scalability for large-scale production

Best for: High-performance aerospace turbine components and jet engines

3. PREP (Plasma Rotating Electrode Process)

Process:

• A rotating Ti-6Al-2Sn-4Zr-2Mo electrode is melted by plasma, while centrifugal force atomizes the molten material into fine spherical particles.

Advantages:
✔ Ultra-high purity, with minimal contamination
✔ Highly spherical morphology, leading to excellent flowability
✔ Minimal porosity, making it ideal for high-performance aerospace applications

Disadvantages:
✖ Very high cost
✖ Limited scalability

Best for: Aerospace turbine blades, high-performance structural components requiring high purity

For high-quality additive manufacturing, Met3DP’s gas-atomized Ti-6Al-2Sn-4Zr-2Mo powder is the best choice. Explore Met3DP’s powder production solutions.

Cost Analysis in 2025

The cost of Ti-6Al-2Sn-4Zr-2Mo powder is influenced by several factors, such as production method, particle morphology, purity level, and application-specific requirements.

Factors Affecting Cost

1. Production Method – PREP and plasma-atomized powders are the most expensive, while gas-atomized powders offer a more balanced cost-performance ratio.
2. Particle Shape – Spherical powders (for AM) are more expensive than irregular powders.
3. Purity Level – Higher purity = Higher cost.
4. Market Demand – Increased demand from aerospace, automotive, and high-performance applications influences pricing.

Estimated Price Ranges

For cost-effective, high-quality Ti-6Al-2Sn-4Zr-2Mo powder, Met3DP provides precision-engineered solutions tailored to industrial needs. Contact Met3DP for pricing and availability.

FAQ

Q1: What is the best Ti-6Al-2Sn-4Zr-2Mo powder for 3D printing?

Gas-atomized spherical Ti-6Al-2Sn-4Zr-2Mo powder is optimal for LPBF, EBM, and DED due to its excellent flowability and low oxygen content.

Q2: How does Ti-6Al-2Sn-4Zr-2Mo compare to Ti-6Al-4V?

Ti-6Al-2Sn-4Zr-2Mo offers superior high-temperature strength and oxidation resistance, whereas Ti-6Al-4V provides better overall ductility and toughness.

Q3: Can Ti-6Al-2Sn-4Zr-2Mo powder be used for aerospace applications?

Yes, Ti-6Al-2Sn-4Zr-2Mo is widely used in aerospace for turbine blades, jet engines, and high-temperature structural components due to its high strength and oxidation resistance.

Q4: Where can I buy high-quality Ti-6Al-2Sn-4Zr-2Mo powder?

Met3DP is a leading supplier of gas-atomized Ti-6Al-2Sn-4Zr-2Mo powder, optimized for 3D printing and high-performance applications. Contact Met3DP today!

Conclusion

Ti-6Al-2Sn-4Zr-2Mo powder is an exceptional high-performance titanium alloy for aerospace, automotive, additive manufacturing, and high-temperature applications. Choosing the right powder type, production method, and supplier ensures optimal performance and reliability.

Why Choose Met3DP’s Ti-6Al-2Sn-4Zr-2Mo Powder?

✅ Industry-leading gas atomization technology
✅ High-purity spherical powders for additive manufacturing
✅ Reliable supply chain & global distribution

For high-performance Ti-6Al-2Sn-4Zr-2Mo powder, Met3DP provides state-of-the-art solutions tailored to industrial demands.

Want to learn more or get a quote? Contact Met3DP today!