Ti6Al4V Powder

Overview

Ti6Al4V powder, also known as Ti-6Al-4V, Grade 5 titanium, Ti 6-4 or Ti 6/4, is a titanium alloy powder consisting of titanium, 6% aluminum and 4% vanadium. It offers an exceptional combination of high strength, low weight, corrosion resistance and biocompatibility which makes it an extremely versatile material for advanced applications in aerospace, medical devices, marine hardware and more.

Ti6Al4V is considered the workhorse of titanium alloys, accounting for over 50% of total titanium usage the world over. It has among the best strength-to-weight ratios of any metallic material and maintains its properties at extreme temperatures.

Some key properties and characteristics of Ti6Al4V powder include:

• Excellent strength-to-weight ratio, high specific strength
• Low density – 4.43 g/cm3
• High corrosion resistance
• Biocompatibility and osseointegration ability
• Good high temperature properties – usable up to 400°C with oxidation resistance up to 550°C
• High fracture toughness and fatigue strength
• Available in different size ranges and morphologies – spherical, angular

With its versatile properties, Ti6Al4V finds diverse applications across industries today.

Ti6Al4V Powder Types

Ti6Al4V alloy powder is available in different size distributions, shapes and production methods to suit specific applications:

Type	Characteristics
Gas atomized spherical	– Near spherical morphology, smooth surface – Tight particle size control – Used in AM, MIM, thermal spray
Plasma atomized spherical	– Highly spherical with smooth surface – Narrow size distribution – Used in AM processes
Hydride-dehydride (HDH)	– Irregular, angular morphology – Porous, spongy particles – Lower production cost – Used in MIM, pressing, thermal spray

Particle Size: Available from 15 microns to 150+ microns depending on production method

Size Distribution: Graded/sieved, blended or custom specifications

Standards: ASTM B348, AMS 4943, AMS 4928, AMS 4967

Ti6Al4V Powder Composition

Ti6Al4V conforms to Aerospace Material Specification (AMS) 4928 and has the nominal composition:

Element	Composition Range
Titanium	Balance, 87.725 – 91%
Aluminum	5.5 – 6.76%
Vanadium	3.5 – 4.5%
Iron	Max 0.30%
Oxygen	Max 0.20%
Nitrogen	Max 0.05%
Carbon	Max 0.08%
Hydrogen	Max 0.015%

Iron, oxygen and nitrogen are commonly found impurity elements. The composition is routinely analyzed to ensure it meets aerospace grade specifications before atomization into powder.

Ti6Al4V Powder Properties

Ti6Al4V is prized for its exceptional balance of mechanical properties, corrosion resistance, lightness and biocompatibility. Its properties include:

Physical & Mechanical Properties	Values
Density	4.43 g/cm3
Melting Point	1604 – 1660°C
Ultimate Tensile Strength	860 – 965 MPa
Yield Strength (0.2% offset)	795 – 875 MPa
Modulus of Elasticity	114 GPa
Elongation at Break	10 – 18%
Hardness	334 – 361 HV
Fatigue Strength (107 cycles)	400 – 490 MPa
Fracture Toughness	55 – 115 MPa-m^0.5

Thermal Properties
Coefficient of Thermal Expansion – 8.6 x 10-6 /K (20-100°C)
Thermal Conductivity – 7.2 W/m.K
Maximum Service Temperature – 400°C

Corrosion Resistance
Excellent corrosion resistance comparable to unalloyed titanium Resists corrosion by most acids, moist gases, organic chemicals

Formation of stable and highly adhesive oxide surface layer gives it excellent resistance to saline environments. Ti6Al4V demonstrates protection superior to stainless steel in chloride solutions due to lower oxygen and chloride diffusion rates.

Ti6Al4V Powder Applications

Thanks to its well-balanced properties, Ti6Al4V finds diverse industrial and medical applications today:

Industry	Applications
Aerospace	– Aircraft structural components like wings, landing gear, turbines, fasteners – Rocket motor casings, space vehicles – Helicopter rotor hub, compressor blades
Medical & Dental	– Orthopedic implants – hip, knee joints – Dental implants, fixtures, crowns – Maxillofacial implants – Surgical instruments
Automotive	– Connecting rods, drive shafts, springs – Racing car parts like valves, pistons – Exhaust components
Chemical	– Heat exchangers, tanks, pipes carrying corrosive media – Valves, condensers, distillation columns – Pumps and housings
Power & Energy	– Steam and gas turbine components – Structural parts for reactors – Renewables -high performance offshore
Marine	– Propellers, connecting rods – Corrosion resistant fasteners, hinges – Desalination equipment

Additive manufacturing is expanding the applications for titanium alloys in all these sectors by enabling freeform geometries not possible previously.

Ti6Al4V Powder Specifications

Standard	Description
ASTM B348	Standard specification for titanium and titanium alloy bars and billets
AMS 4928	Aerospace material specification for titanium alloy sheet, strip and plate 6Al – 4V annealed
AMS 4943	Chemical check analysis limits for titanium and titanium alloys
AMS 4967	Aerospace material specification for powder, titanium alloy 6Al-4V
ISO 21388	Specification for unalloyed titanium for surgical implant applications
ASME SB-348	Specification for titanium and titanium alloy bars and billets

Titanium grade 5 Eli powder also needs to meet additional customer requirements pertaining to:

• Particle shape
• Flowability
• Apparent density
• Tap density
• Pycnometer density
• Chemical analysis
• Mechanical properties

Manufacturers producing Ti6Al4V powder follow certified quality management systems and testing protocols before supplying to customers across defense, aerospace, energy, motorsports and medical sectors among others.

Ti6Al4V Powder Suppliers

Ti6Al4V powder is manufactured via gas atomization or plasma atomization to produce spherical powder suitable for AM. The starting raw material is vacuum arc remelted (VAR) or electron beam melted (EBM) alloy slab which is atomized into fine droplets that solidify into powder particles on rapid cooling.

Key global suppliers of Ti6Al4V spherical and pre-alloyed powders are:

Company	Country
AP&C	Canada
ATI Powder Metals	USA
TLS Technik GmbH	Germany
GKN Hoeganaes	USA
Tekna Advanced Materials	USA
Slm Solutions	Germany
Erasteel	France

Ti6Al4V powder can be procured in small quantities for research and prototyping applications. Custom alloys and particle characteristics are also possible for companies with established supply agreements.

Pricing:
As a high performance alloy requiring advanced manufacturing, Ti6Al4V powder commands a premium over standard grades of titanium and other metal powders. Pricing varies from $100/kg to $500/kg based on:

• Order quantity
• Particle shape and size distribution
• Customization of chemistry/mechanical properties
• Testing and certification requirements
• Economic factors – supply-demand dynamics, raw material costs

Higher purity grades used in medical devices and aerospace applications are costlier. Costs have seen a declining trend with ramp up in production capacities globally.

How to Choose Ti6Al4V Powder

Selection of appropriate Ti6Al4V powder depends upon your specific application and process requirements. Some key considerations include:

Additive Manufacturing

• Particle shape – spherical/shaped distributions for better flow and packing
• Particle size – fine <45 microns for better resolution and surface finish
• Narrow size range – ensures uniform melting and densification
• High powder purity >99.5% titanium for lower contamination
• Low oxygen, nitrogen and carbon content

Metal Injection Molding (MIM)

• Irregular, angular powder for higher green strength
• Medium particle size – 100 mesh
• Powder blend with binder components
• Economic grade meeting cost targets

Thermal Spray

• Particle size suitable for spray process
• Porous HDH hydride powder allows better coating bonding
• Custom alloy development possible

Powder Metallurgy

• Angular, porous powder for compaction
• Powder blend tailored to application
• Alloy modified for sintering response

Do consult powder producers early in the design process to select the optimum powder suited for your specific component requirements.

Advantages and Limitations of Ti6Al4V Powder

Advantages

• High strength to weight ratio
• Retains properties at elevated temperatures
• Excellent corrosion resistance
• Bioinert – does not produce adverse reactions when implanted
• Powder feedstock allows complex, net-shape part fabrication via AM
• Tailorable mechanical properties by heat treatment
• Recyclable to minimize wastage

Limitations

• High material cost compared to steels and aluminum alloys
• Requires high processing temperatures oxygen contamination risk
• Lower stiffness than steel
• Sharp notch sensitivity – cracking risk
• Difficult to machine requiring special tooling

Engineers select Ti6Al4V where strength, temperature resistance, biocompatibility and corrosion resistance needs outweigh cost constraints in critical structural parts.

Ti6Al4V Powder vs. Alternatives

Ti6Al4V competes against stainless steels, cobalt chromium alloys, aluminum grades and pure titanium. Comparison on key parameters is highlighted below:

	Ti6Al4V	Stainless Steel 316L	CoCrMo Alloy	Al 6061	Pure Ti Grade 2
Yield Strength	860 MPa	290 MPa	655 MPa	55 MPa	370 MPa
Density	4.43 g/cc	8 g/cc	8.3 g/cc	2.7 g/cc	4.51 g/cc
Young’s Modulus	114 GPa	193 GPa	230 GPa	69 GPa	105 GPa
Thermal Conductivity	7 W/mK	12 W/mK	9 W/mK	180 W/mK	7 W/mK
Melting Point	1640°C	1375°C	1350°C	650°C	1668°C
Corrosion Resistance	Excellent	Good	Fair	Good	Excellent
Cost Comparison	10x vs Al, 4x vs Steel	Lower cost base	2x cost vs steel	Lowest cost	8x cost vs Ti grade 2

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Additional FAQs on Ti6Al4V Powder

1) What oxygen and hydrogen limits should I target for AM-grade Ti6Al4V powder?

• For aerospace/medical-grade AM feedstock, typical targets are O ≤ 0.15 wt% (ELI grades even lower, ~0.10–0.13 wt%) and H ≤ 0.012–0.015 wt%. Lower interstitials improve ductility and fatigue.

2) Which particle size distribution works best for LPBF vs. EBM?

• LPBF commonly uses 15–45 μm or 20–53 μm cuts. EBM typically prefers coarser 45–106 μm to suit high-temperature spreading in vacuum and reduce “smoke” events.

3) How many reuse cycles are acceptable for Ti6Al4V powder in LPBF?

• With O2/H2O monitoring, sieving, and blend-back strategies, 3–8 cycles are typical. Establish property-based end-of-life criteria (tensile, elongation, fatigue) per ISO/ASTM 52907 and internal specs.

4) What post-processing most improves fatigue of AM Ti6Al4V parts?

• Hot isostatic pressing (HIP) to close internal porosity, followed by stress relief or solution + aging as required. Surface finishing (shot peening, machining) to remove notch-like roughness further boosts HCF/LCF.

5) Are there printable variants beyond Grade 5, such as Ti6Al4V ELI?

• Yes. Ti6Al4V ELI (Grade 23) has tighter interstitial limits (especially O) for improved toughness/ductility, widely used in medical implants. Powder and process controls must align with ELI chemistry limits.

2025 Industry Trends for Ti6Al4V Powder

• Qualification at scale: More OEMs implementing lot-level digital material passports linking powder chemistry, reuse cycles, and part serials for aerospace/medical audits.
• Cost and sustainability: Increased recycled Ti feedstock and energy-optimized atomization; suppliers publishing EPDs. Prices stabilizing after 2023–2024 volatility.
• Process windows widen: Multi-laser LPBF and advanced recoaters tolerate slightly broader PSD while maintaining density, boosting yield from atomization.
• Surface integrity focus: Standardization of post-processing routes (HIP + mechanical finishing) to meet fatigue allowables for safety-critical parts.
• Powder hygiene automation: Inline O2/H2O analyzers and sealed handling reduce interstitial pickup across reuse, especially in humid regions.

2025 Snapshot: Ti6Al4V Powder Market and Technical Metrics (indicative ranges)

Metric (2025)	Value/Range	Notes/Sources
AM-grade Ti6Al4V powder price	$140–$280/kg	Cut, morphology, certification dependent; supplier price lists and RFQs
Typical LPBF density (optimized)	≥99.8–99.95%	Process parameter + HIP dependent
Oxygen target (Grade 5 AM powder)	≤0.15 wt%	ISO/ASTM 52907, AMS 4999/4967 context
Common PSD (LPBF / EBM)	15–45 μm / 45–106 μm	OEM parameter guides
Reuse cycles (controlled)	3–8	With sieving + O2 monitoring
HIP adoption (critical parts)	70–90%	Aerospace/medical market norms

References: ISO/ASTM 52907, 52920, 52930; AMS 4967/4999; OEM application notes (EOS, GE Additive/Arcam, Renishaw, SLM Solutions); peer‑reviewed AM Ti6Al4V fatigue studies (2019–2025).

Latest Research Cases

Case Study 1: Extending Powder Reuse While Preserving Fatigue in LPBF Ti6Al4V (2025)

• Background: An aerospace Tier-1 sought to reduce powder scrap without compromising HCF life of flight brackets.
• Solution: Implemented sealed conveyance, inline O2/H2O monitoring, sieve to 20–53 μm, and 20% virgin blend-back per cycle; standardized HIP + surface machining.
• Results: Oxygen growth limited to +0.01–0.02 wt% over 6 cycles; as-built density ≥99.9%; HCF at R=0.1 improved 15% post-HIP vs. legacy route; powder scrap reduced 28%.

Case Study 2: Ti6Al4V ELI Lattice Implants with Controlled Surface Roughness (2024)

• Background: A medical OEM needed consistent pore morphology and fatigue for acetabular cups while retaining osseointegration surfaces.
• Solution: Narrow PSD 15–45 μm ELI powder, tuned LPBF parameters for strut fusion, HIP, and selective finishing (external machining, lattice preserved).
• Results: CT-measured pore uniformity CV reduced from 8.0% to 3.5%; static strength unchanged; rotating bending fatigue life +20%; passed biocompatibility and cleanliness audits.

Expert Opinions

• Prof. Iain Todd, Professor of Metallurgy and Materials Processing, University of Sheffield
• Viewpoint: “Interstitial control in Ti6Al4V—especially oxygen—is the primary lever for reliable ductility and fatigue. Powder handling can make or break qualification.”
• Source: Academic publications and AM conferences
• Dr. Martina Zimmermann, Head of Materials, Fraunhofer IAPT
• Viewpoint: “Digital traceability from powder lot to part serial, paired with HIP and targeted finishing, is becoming standard for safety‑critical Ti components.”
• Source: Fraunhofer IAPT technical communications
• Kevin Slattery, VP Materials Engineering, Carpenter Additive
• Viewpoint: “Yield gains from atomization plus smarter PSD cuts are narrowing cost gaps; customers now value proven hygiene workflows as much as price.”
• Source: Industry panels and supplier briefs

Practical Tools and Resources

• Standards and qualification
• ISO/ASTM 52907 (AM feedstock), 52920/52930 (process/quality): https://www.iso.org
• AMS 4967/4999 and ASTM F3001 (additive Ti6Al4V): https://www.sae.org and https://www.astm.org
• OEM technical libraries
• EOS, Renishaw, SLM Solutions, GE Additive/Arcam parameter and handling guides
• Powder testing methods
• ASTM B214 (sieve analysis), B212 (apparent density), B964 (Hall flow), inert gas fusion for O/N/H (ASTM E1409/E1447)
• Design and post-processing
• nTopology/Ansys Additive/Altair for lattice/topology optimization; HIP service provider data sheets (QPs for Ti6Al4V)
• Safety
• NFPA 484 guidance for combustible titanium powders: https://www.nfpa.org

Last updated: 2025-10-16
Changelog: Added 5 Ti6Al4V FAQs; included 2025 trend table with market/technical metrics; added two 2024/2025 case studies; compiled expert viewpoints; linked standards, OEM guides, testing methods, and safety resources
Next review date & triggers: 2026-03-31 or earlier if ISO/ASTM/AMS specs are revised, major OEMs update Ti6Al4V parameter windows, or supply/demand shifts move prices >15% for AM-grade powder