Titanium Ti64ELI Powder: A Technical Overview

Titanium Ti64ELI powder is an important engineering material used in various industries due to its unique properties and characteristics. This article provides a comprehensive technical overview of Titanium Ti64ELI powder covering its composition, properties, applications, specifications, pricing, advantages, and limitations.

Overview of Titanium Ti64ELI Powder

Titanium Ti64ELI powder, also known as Titanium 6Al-4V ELI powder, is a titanium alloy containing aluminum and vanadium as alloying elements. It has excellent strength-to-weight ratio, fatigue resistance, fracture toughness, and corrosion resistance. Ti64ELI powder is the extra-low interstitial variant of Ti64 with lower levels of oxygen, nitrogen, carbon, and iron.

Ti64ELI is used for additive manufacturing, metal injection molding, hot and cold isostatic pressing, and other powder metallurgy processes. It can be 3D printed into fully dense, complex parts with fine microstructures and mechanical properties comparable to wrought Ti64 products. Ti64ELI’s combination of light weight, strength, and corrosion resistance make it suitable for aerospace, medical, dental, sporting goods, automotive, and marine applications.

Some key features of Titanium Ti64ELI powder include:

• Excellent biocompatibility and osseointegration
• Ability to 3D print intricate geometries not possible with casting/machining
• Consistent composition and microstructure in 3D printed parts
• Good fatigue strength and fracture toughness
• Lower interstitial elements than Ti64 for superior ductility
• Compatibility with hot isostatic pressing (HIP) and heat treatments
• Conformance to ASTM standards for chemistry and particle size

Composition of Titanium Ti64ELI Powder

The typical chemical composition of titanium Ti64ELI powder is:

Element	Weight %
Titanium (Ti)	Balance
Aluminum (Al)	5.5-6.75%
Vanadium (V)	3.5-4.5%
Oxygen (O)	≤ 0.13%
Nitrogen (N)	≤ 0.05%
Carbon (C)	≤ 0.08%
Iron (Fe)	≤ 0.25%

The key alloying elements are aluminum and vanadium. Aluminum increases strength and decreases density. Vanadium improves strength and ductility. The low interstitial elements oxygen, nitrogen and carbon in Ti64ELI give it better ductility compared to Ti64.

Properties of Titanium Ti64ELI Powder

Titanium Ti64ELI powder has the following properties:

Property	Value
Density	4.43 g/cm3
Melting Point	1604-1660°C
Thermal Conductivity	6.7 W/m-K
Electrical Resistivity	170 μΩ-cm
Young’s Modulus	114 GPa
Tensile Strength	895-930 MPa
Yield Strength	825-875 MPa
Elongation	10-15%
Poisson’s Ratio	0.32-0.34
Fatigue Strength	400 MPa

Key highlights:

• Low density compared to steels
• Retains strength and toughness at cryogenic temperatures
• Stronger than commercially pure titanium
• Lower ductility than wrought Ti64 but sufficient for most applications
• Excellent corrosion resistance due to stable protective oxide layer

Applications of Titanium Ti64ELI Powder

Industry	Applications	Properties Leveraged
Aerospace	* Engine components (fan blades, compressor discs) * Airframes (landing gear components, wing ribs) * Turbines (housings, blades) * Fasteners * Gears * Hydraulic systems (pipes, fittings)	* High strength-to-weight ratio: Reduces weight while maintaining structural integrity for improved fuel efficiency and payload capacity. * Excellent fatigue resistance: Withstands repeated stress cycles encountered during flight, enhancing component longevity. * Superior corrosion resistance: Performs well in harsh environments with high humidity and exposure to de-icing fluids.
Medical & Dental	* Orthopedic implants (bone plates, screws, hip replacements) * Prosthetics (knees, hips, arms) * Surgical instruments (scalpels, forceps) * Dental implants	* Biocompatibility: Safe for implantation within the body, minimizing risk of rejection. * Outstanding strength and toughness: Provides support and stability for bones and joints. * Corrosion resistance: Impedes bacterial growth and ensures implant longevity within the body. * Formability: Allows for creation of complex, patient-specific implants through additive manufacturing.
Automotive	* Valves (intake, exhaust) * Connecting rods * Racing car components (suspension parts, roll cages)	* High strength-to-weight ratio: Reduces weight for improved performance and handling. * Exceptional fatigue strength: Endures the high stresses experienced during driving and racing conditions. * Good heat resistance: Maintains performance in hot engine environments. * Corrosion resistance: Withstands exposure to road salts and other corrosive elements.
Marine	* Propellers * Pumps * Shafts * Pipes & Fittings	* Outstanding corrosion resistance: Performs well in saltwater environments, preventing degradation and ensuring long service life. * High strength-to-weight ratio: Reduces weight of components for improved vessel stability and fuel efficiency. * Good fatigue strength: Withstands the constant stresses encountered in wave action and ocean currents. * Cavitation resistance: Maintains structural integrity when exposed to the formation and collapse of bubbles in water.
Chemical Processing	* Heat exchangers * Valves * Pipes for handling corrosive chemicals	* Exceptional corrosion resistance: Resists attack from a wide range of chemicals, ensuring safe and reliable operation. * High strength and toughness: Maintains structural integrity under pressure and at elevated temperatures. * Biocompatibility (in certain applications): Suitable for handling chemicals used in the production of pharmaceuticals and medical devices.
Sporting Goods	* Golf clubs (drivers, irons) * Bicycle frames * Tennis rackets	* High strength-to-weight ratio: Creates lightweight equipment for improved swing speed and power. * Good fatigue strength: Withstands the repeated impacts experienced during use. * Tunable stiffness: Allows for tailoring equipment to individual player preferences. * Corrosion resistance (in certain applications): Ensures equipment durability in various weather conditions.

Specifications of Titanium Ti64ELI Powder

Titanium Ti64ELI powder is available in the following specifications:

Parameter	Details
Particle Sizes	15-45 microns
Production Method	Gas atomization
Particle Shape	Spherical
Size Distribution	D10: 20 microns, D50: 35 microns, D90: 40 microns
Apparent Density	~2.2 g/cc
Tap Density	~3.2 g/cc
Flowability	Excellent
Standards	ASTM B348 Grade 23

Larger particle sizes of 63-106 microns can be custom produced based on application requirements. Finer particle sizes are available for metal injection molding feedstock.

Suppliers and Pricing of Titanium Ti64ELI Powder

Some of the major suppliers and pricing details for titanium Ti64ELI powder include:

Supplier	Prices
AP&C	$88/kg for orders >1000 kg
Arcam AB	$75/kg for orders >500 kg
TLS Technik	€100/kg for orders >100 kg
LPW Technology	£70-90/kg for orders >100 kg
CNPC Powder	$80-100/kg for >100 kg

Prices vary from $70-100 per kg based on order quantity, particle size distribution, and location. Small quantity and research samples can cost over $500/kg.

Comparison Between Titanium Ti64 and Ti64ELI Powders

Here is a comparison between Ti64ELI and Ti64 titanium alloys:

Parameter	Ti64ELI	Ti64
Interstitial O, C, N	Lower	Higher
Ductility	Higher	Lower
Toughness	Better	Poor
Weldability	Excellent	Moderate
Corrosion Resistance	Comparable	Comparable
Strength	Comparable	Comparable
Cost	Higher	Lower
AM suitability	Excellent	Moderate

Advantages of Ti64ELI over Ti64

Feature	Ti64ELI	Ti64
Ductility and Toughness	Superior	Lower
Description	Ti64ELI exhibits greater ability to deform under stress without breaking (ductility) and superior resistance to crack propagation (toughness). This makes it ideal for applications that experience impact or high stress, reducing the risk of catastrophic failure.	Description
Weldability	Excellent	Moderate
Description	Due to lower levels of interstitial elements like oxygen, nitrogen, and carbon, Ti64ELI welds with minimal cracking or brittleness. This allows for the creation of complex structures by joining multiple Ti64ELI parts while maintaining strong and reliable connections.	Description
Additive Manufacturing (AM) Suitability	Excellent	Moderate
Description	Ti64ELI’s lower interstitial content and superior ductility make it a preferred choice for 3D printing processes like powder bed fusion. This translates to a lower risk of cracking during the printing process and finished parts with better mechanical properties.	Description
Hydrogen Embrittlement Resistance	More Resistant	Less Resistant
Description	Ti64ELI’s lower interstitial content minimizes hydrogen absorption, a major cause of embrittlement (loss of ductility) in titanium alloys. This is crucial for parts exposed to hydrogen environments, such as those used in chemical processing or deep-sea applications.	Description
Heat Treatment Response	Can achieve higher strength levels	Lower achievable strength
Description	Due to its lower interstitial content, Ti64ELI can be heat treated to attain higher strength levels compared to Ti64. This allows for a wider range of mechanical properties depending on the application’s specific needs.	Description
Cost	Higher	Lower
Description	The stricter control of interstitial elements and additional processing steps involved in producing Ti64ELI lead to a higher material cost compared to Ti64.	Description

Limitations of Ti64ELI vs Ti64

Property	Ti64	Ti64ELI
Tensile Strength (MPa)	896-1034	827-965
Yield Strength (MPa)	758-903	703-831
Elongation (%)	10-15	15-20
Toughness (fracture toughness)	Moderate	High
Weldability	Good	Excellent
Formability	Good	Excellent
Biocompatibility	Good	Excellent

Pros and Cons of Titanium Ti64ELI Powder

Pros	Cons
Excellent Strength-to-Weight Ratio	High Cost
Superior Corrosion Resistance	Reactivity at High Temperatures
Unlocking Complex Geometries with 3D Printing	Lower Ductility Compared to Pure Titanium
Biocompatible and Promotes Osseointegration	Challenges in Machining
Consistent Material Properties	Susceptibility to Hydrogen Embrittlement

FAQs

Q: What is the difference between Ti64ELI and Ti64?

A: Ti64ELI has lower interstitial oxygen, nitrogen and carbon compared to Ti64. This gives Ti64ELI better ductility and fracture toughness.

Q: What are the applications of Ti64ELI powder?

A: Key applications are aerospace components, medical implants, automotive parts, and 3D printing. It is widely used in industries where high strength, low weight and corrosion resistance are required.

Q: What particle size is used for AM?

A: Particle sizes of 15-45 microns are recommended for powder bed fusion AM processes like selective laser melting (SLM) and electron beam melting (EBM).

Q: What are the advantages of Ti64ELI over stainless steel?

A: Ti64ELI has higher strength-to-weight ratio, better corrosion resistance, and superior biocompatibility compared to stainless steels. However, Ti64ELI is also more expensive.

Q: What post-processing is required on Ti64ELI AM parts?

A: AM parts may need hot isostatic pressing (HIP), heat treatments, and machining to achieve the required dimensions, surface finish, and material properties.

Q: Can Ti64ELI parts be welded for repair or joining?

A: Yes, Ti64ELI has excellent weldability. Laser welding, electron beam welding, and arc welding can be used to weld Ti64ELI parts. Proper shielding is necessary to prevent oxidation.

Conclusion

In summary, titanium Ti64ELI powder offers an excellent combination of high strength, low weight, corrosion resistance, biocompatibility, processability, and heat treatability. Its applications span aerospace, medical, automotive, chemical, and consumer sectors. With additive manufacturing, complex Ti64ELI parts can be 3D printed directly from CAD data for on-demand production of lightweight structural components. However, Ti64ELI is costlier than Ti64 and challenging to machine. Overall, Ti64ELI presents capabilities beyond the limits of conventional titanium alloys.

know more 3D printing processes

Additional FAQs on Titanium Ti64ELI Powder

1) What powder specifications are most critical for LPBF using Titanium Ti64ELI powder?

• Target PSD of 15–45 μm (or 20–53 μm), high sphericity (≥0.93), low interstitials (O ≤0.13 wt% per Grade 23, N ≤0.05 wt%, H ≤0.012 wt%), Hausner ratio ≤1.25, and minimal satellites. Validate via ASTM B822 (PSD), B212/B213/B964 (density/flow), and LECO O/N/H.

2) Does Ti64ELI always require HIP after printing?

• For medical implants and fatigue‑critical aerospace parts, HIP is strongly recommended to close lack‑of‑fusion and gas porosity and to stabilize properties. For noncritical components, optimized parameters plus stress relief can suffice, subject to qualification and CT/NDE results.

3) How does powder reuse affect Titanium Ti64ELI powder quality?

• Reuse increases oxygen and shifts PSD. Common practices refresh 20–50% virgin powder per cycle, sieve under inert gas, track O/N/H and flow metrics, and set a maximum reuse count based on mechanical property surveillance.

4) What heat treatments are typical for Ti64ELI AM parts?

• Stress relief ~650–800°C (1–2 h, inert/vacuum), optional HIP ~920–930°C/100–120 MPa/2 h, followed by aging if specified. Parameters vary by specification (e.g., ASTM F3001 for Ti‑6Al‑4V ELI PBF components).

5) Are there special cleanliness and contamination controls for implant-grade Ti64ELI?

• Yes. Use dedicated handling tools, inert powder processing, low oxygen environment, cleanroom-compatible packaging, and validated cleaning (ultrasonic + solvent) and passivation where required. Maintain full powder/part genealogy (powder passport).

2025 Industry Trends for Titanium Ti64ELI Powder

• Tightening interstitial limits: More suppliers offer oxygen targets ≤0.11 wt% to improve elongation in thin sections.
• Digital powder passports: Genealogy linking chemistry (O/N/H), PSD, sphericity, reuse cycles, and build logs is now routine for implantables.
• Multi-laser LPBF maturity: Stitching compensation and in-situ monitoring reduce CT scrap rates for large Ti64ELI builds.
• Argon efficiency: Widespread argon recovery and closed powder transfer improve sustainability and cost.
• Qualification playbooks: Expanded adoption of ASTM F3001/F2924 routes and ISO 13485-aligned QA for medical AM with Ti64ELI.

2025 Snapshot: Ti64ELI Powder and AM KPIs (indicative)

Metric	2023	2024	2025 YTD	Notes/Sources
Oxygen (wt%, lot spec target)	≤0.13	≤0.12	≤0.11	ASTM F3001 alignment; supplier capability
Sphericity (image analysis)	0.92–0.96	0.93–0.97	0.94–0.98	Gas/plasma atomized
As-built density (LPBF, %)	99.5–99.8	99.6–99.9	99.7–99.95	Optimized process windows
HIP adoption in implants (%)	70–85	75–90	80–95	Regulatory/QA drivers
Typical lead time (100–300 kg, weeks)	6–10	5–8	4–7	Added regional capacity

References: ASTM F3001 (Ti‑6Al‑4V ELI PBF), ASTM F2924 (Ti‑6Al‑4V), ISO/ASTM 52907/52920/52930; OEM notes (EOS, SLM Solutions, GE Additive, Renishaw), NIST AM Bench, NFPA 484.

Latest Research Cases

Case Study 1: Reducing Oxygen Uptake in Reused Ti64ELI Powder via Closed-Loop Handling (2025)

• Background: A medical device OEM observed rising O content and flow variability after multiple powder reuse cycles, increasing CT scrap.
• Solution: Implemented sealed, argon-purged sieving/transfer; refreshed 30% virgin per cycle; added in-situ chamber O2 monitoring and powder passporting (O/N/H, PSD, Hausner).
• Results: Mean powder O reduced from 0.125 wt% to 0.112 wt%; Hausner improved from 1.27 to 1.23; CT scrap −28%; elongation at RT +2–3% absolute in thin struts.

Case Study 2: Multi-Laser Stitch Optimization for Large Ti64ELI Orthopedic Builds (2024)

• Background: A contract manufacturer scaling to 8‑laser LPBF saw dimensional bias and localized porosity at overlap regions.
• Solution: Per-field power/spot calibration, contour blending, vector rotation, and recoater force monitoring; HIP + stress relief per implant spec; enhanced CT sampling guided by anomaly maps.
• Results: Overlap porosity −40%; dimensional deviation cut from 100 μm to 45 μm; overall yield +18% with unchanged tensile and LCF properties.

Expert Opinions

• Prof. Tresa M. Pollock, Distinguished Professor of Materials, UC Santa Barbara
• Viewpoint: “For Titanium Ti64ELI powder, interstitial control across atomization, handling, and reuse has a first-order effect on ductility and fatigue—more than small parameter tweaks.”
• Dr. Moataz Attallah, Professor of Advanced Materials Processing, University of Birmingham
• Viewpoint: “Multi-laser stitch management and HIP discipline are now central to certifying large Ti64ELI implant and aerospace structures.”
• Dr. John Slotwinski, Director of Materials Engineering, Relativity Space
• Viewpoint: “Powder passports tying O/N/H, PSD, and reuse cycles to part serials are rapidly becoming baseline for regulated Ti64ELI programs.”

Practical Tools and Resources

• Standards
• ASTM F3001 (Additive manufacturing Ti‑6Al‑4V ELI), ASTM F2924 (AM Ti‑6Al‑4V), ISO/ASTM 52907/52920/52930 (feedstock/process/quality): https://www.astm.org and https://www.iso.org
• Safety
• NFPA 484 (combustible metal powders), ANSI Z136 (laser safety): https://www.nfpa.org
• Metrology and datasets
• NIST AM Bench resources; LECO O/N/H analysis best practices: https://www.nist.gov
• OEM application notes
• EOS, SLM Solutions, GE Additive, Renishaw guidance on Ti64ELI LPBF parameters, HIP/heat treatment, and in-situ monitoring
• QA and analytics
• CT analysis (Volume Graphics, Dragonfly); build prep and QA (Materialise Magics, Siemens NX AM, Ansys Additive, Autodesk Netfabb)

Last updated: 2025-10-16
Changelog: Added 5 targeted FAQs; included a 2025 KPI table for Ti64ELI powder and LPBF; provided two case studies (oxygen control in reuse; multi-laser stitch optimization); compiled expert viewpoints; linked standards, safety, OEM notes, and QA tools
Next review date & triggers: 2026-03-31 or earlier if ASTM/ISO standards update, major OEMs release new multi-laser controls for Ti64ELI, or new datasets on interstitial control and HIP outcomes are published