Ti-6Al-4V Grade 5
metaltitanium alloy — alpha-beta
Ti64TC4Grade 5 TitaniumUNS R56400TiAlV 6-4
Composition — UNS R56400 / ASTM F2924-14
| Element | Min % | Max % | Notes |
|---|---|---|---|
| Ti | bal. | balance | |
| Al | 5.50 | 6.750 | |
| V | 3.50 | 4.500 | |
| Fe | — | 0.300 | |
| O | — | 0.200 | Key interstitial — strength increases with O content but ductility decreases |
| N | — | 0.050 | |
| C | — | 0.080 | |
| H | — | 0.015 | Hydrogen embrittlement risk; controlled atmosphere mandatory during LPBF |
| Y | — | 0.005 |
Mechanical & thermal properties — 6 conditions
| Property | LPBF as-built (XY) | LPBF as-built (Z) | LPBF stress-relieved (600–650°C / 2–4h / Ar) | LPBF annealed (730–800°C / 2h / furnace cool) | LPBF + HIP (920°C / 100 MPa / 2h) | EBM as-built |
|---|---|---|---|---|---|---|
| Elastic modulus | 105–120 GPa | — | — | 110–118 GPa | — | 110–120 GPa |
| Yield strength (0.2%) | 990–1180 MPa | 940–1120 MPa | 950–1100 MPa | 825–1050 MPa | 830–970 MPa | 820–970 MPa |
| Ultimate tensile strength | 1150–1400 MPa | 1060–1280 MPa | 1050–1230 MPa | 895–1150 MPa | 895–1060 MPa | 895–1050 MPa |
| Elongation at break | 4.0–10.0 % | 3.0–8.0 % | 5.0–12.0 % | 8.0–14.0 % | 12.0–20.0 % | 10.0–18.0 % |
| Hardness (HV) | 350–430 HV10 | — | — | 310–370 HV10 | — | 300–360 HV10 |
| Fatigue strength | — | — | — | 450–650 MPa | 600–800 MPa | — |
| Fracture toughness KIC | — | — | — | — | 60.0–90.0 MPa√m | — |
| Density | 4.43 g/cm³ | — | — | — | — | — |
| Relative density | 99.0–100.0 % | — | — | — | 100.0 % | — |
| Thermal conductivity | 6.0–7.5 W/m·K | — | — | — | — | — |
| CTE | 8.4–9.0 µm/m·K | — | — | — | — | — |
| As-built surface Ra | 8.0–20.0 µm | — | — | — | — | 20.0–40.0 µm |
Values shown as min–max where a spread is reported, otherwise as typical ± unit. Ranges reflect inter-source variation, not single-sample scatter. All values are for AM-processed specimens unless noted.
Engineering considerations
- Always specify post-condition when referencing mechanical properties — as-built, stress-relieved, annealed, and HIP give very different results
- As-built elongation is typically insufficient for most aerospace specifications — plan for post-HT in the design phase
- For fatigue-critical applications: HIP + machined surfaces is minimum; polished surfaces preferred
- Support removal is challenging — internal supports are often impossible to remove; design to minimise internal supports
- Minimum wall thickness: ~0.3 mm achievable but <0.5 mm walls risk distortion and incomplete fusion
- Residual stress causes distortion on removal from build plate — substrate preheat (150–200°C) and scan strategy selection are key mitigations
- Powder reuse: ASTM F3049 powder characterisation required each lot; typically up to 30 reuse cycles before discard in aerospace
- Colour change from silver-grey to blue/gold on as-built surfaces indicates oxidation — check atmosphere seal integrity
- Electrochemical potential: Ti is noble (very low galvanic corrosion risk) but dissimilar metal contact with aluminium must be insulated
Advantages
- Exceptional specific strength — highest strength-to-density ratio of common AM metals
- Excellent corrosion resistance — passive TiO₂ film, highly resistant to seawater and body fluids
- Biocompatible — ISO 10993-1 and FDA cleared for implantable devices
- Well-characterised in AM — more published data and standards than any other AM metal
- Achieves wrought-equivalent fatigue life after HIP + machined surfaces
- LPBF as-built has no post-HT requirement for many structural (non-fatigue-critical) applications
Limitations
- High cost — raw powder 3–6× more expensive than stainless steel per kg
- Poor thermal conductivity (6–7 W/m·K) — limits heat dissipation applications
- Low hardness and wear resistance — unsuitable for tribological surfaces without coating
- As-built elongation typically 4–8% — may not meet ASTM F2924 ≥10% without annealing
- Sensitive to hydrogen embrittlement — strict atmosphere control required during LPBF (O₂ < 100 ppm, H₂ minimal)
- Difficult to machine after printing — low thermal conductivity causes tool wear; plan for machining allowances
- EBM powder not fully recyclable — particle sintering during build limits reuse ratio
- Flammable as fine powder — strict ATEX/OSHA powder handling protocols required
Typical applications
Structural brackets and frames (aerospace, satellite)Orthopaedic implants — hip, knee, spine (medical)Dental implants and crowns (dental)Turbine engine components — stationary parts (aerospace, energy)Unmanned aerial vehicle (UAV) structuresHigh-performance automotive and motorsport componentsPressure vessels and manifolds (industrial, energy)Heat exchangers with complex internal channelsPatient-specific surgical guides and instruments (medical)Rocket propulsion components (aerospace, defence)
Industries
aerospacemedicaldefencemotorsportindustrialenergy
Standards & certifications
ASTM-F2924established
Ti-6Al-4V Grade 5 parts produced by powder bed fusion (LPBF and EBM)
aerospacemedicaldefenceindustrial
ASTM-F3001established
Ti-6Al-4V ELI (Extra Low Interstitial) — lower O/N/Fe for fracture-critical and medical applications
aerospacemedical
ELI grade has lower interstitial content (O ≤ 0.13%, N ≤ 0.03%) vs. Grade 5. Use for implants and fracture-critical aerospace structures.
AMS-7003established
Ti-6Al-4V LPBF aerospace parts — stricter property minimums than ASTM F2924
aerospacedefence
Required by many Tier 1 aerospace OEMs. UTS minimum 930 MPa (vs. 895 MPa in F2924).
ISO-52904established
Process qualification for safety-critical metal PBF parts
aerospacemedicaldefence
ISO-5832-3established
Wrought Ti-6Al-4V — reference standard for implant property comparison
medical
Wrought reference only. AM Ti-6Al-4V implants must additionally satisfy FDA AM Guidance 2017 or EU MDR Annex II.
Compatible AM processes (5)
Other metal materials
316L Stainless Steelaustenitic stainless steel17-4PH Stainless Steelmartensitic precipitation-hardening stainless steelAlSi10Mgaluminium-silicon alloy (cast grade adapted for AM)AlSi7Mg Aluminium Alloyhypoeutectic Al-Si-Mg precipitation-hardenable aluminium alloyInconel 718nickel superalloy — precipitation-hardenedInconel 625nickel superalloy — solid-solution-strengthenedCoCrMocobalt-chromium alloy (biomedical and aerospace grade)Maraging Steel MS1 (18Ni-300)maraging steel (ultra-high-strength, precipitation-hardened)H13 Tool Steelchromium-molybdenum hot-work tool steel
Related calculators
HT AdvisorStandard stress-relief, solution, and aging cycles for AM metals (Ti-6Al-4V, IN718, 17-4PH, AlSi10Mg, 316L, CuCrZr) per AMS, ASTM F3301, and AMS 5664.DistortionEstimate residual stress and distortion risk index (σ/σ_y) for LPBF and DED builds. Mercelis-Kruth model with preheat sensitivity table.VEDCompute LPBF VED from power, scan speed, hatch, and layer thickness. Includes process windows for common alloys.Melt PoolLPBF / DED melt pool depth, width, and cooling rate from the Rosenthal moving heat source solution. Absorptivity, thermal diffusivity, and solidification velocity.HIPRecommended HIP temperature, pressure, and dwell time for AM metals per ASTM F3301, AMS 2801, and DEF STAN 02-835. Covers Ti alloys, Ni superalloys, steels.FatigueS-N curve estimation for AM metals using the Basquin law. Accounts for surface roughness stress concentration (Kt from Ra), build direction anisotropy, and porosity factor.RoughnessTheoretical Ra and Rz from layer thickness and surface angle (staircase effect). Upward, downward, and vertical faces. LPBF, SLS, FDM, SLA, DED. Per Grimm et al.
Last reviewed: 2026-05-05 · v1 · Sources: ASTM-F2924, ASTM-F3001, ASTM-F3049, ASTM-F3122, AMS-7003, eos-ti64-2023, renishaw-ti64-2023, vrancken-2012-ti64, gong-2014-defects, debroy-2018-review, sames-2016-metallurgy, lewandowski-2016-mechanical, yadollahi-2017-fatigue