mill annealed
at 0.160 lb/in³
FDA approved
service temp
Titanium Ti-6Al-4V: The Strongest Lightweight Metal You Can Machine
Titanium Ti-6Al-4V is the most popular titanium alloy in the world. About 60% of all titanium used goes to this one grade. It is also called Grade 5 titanium.
Why is it so popular? It is strong, light, and tough. It has 130 ksi tensile strength — stronger than most steels. But it weighs only 0.160 lb/in³, which is 45% less than steel. That means you get steel-level strength at almost half the weight.
It also resists corrosion. Seawater, body fluids, and most chemicals cannot damage it. The FDA approved it for medical implants because the human body does not reject it. Surgeons use it for hip replacements, knee replacements, dental implants, and bone screws.
The catch? It is hard to machine. Titanium has very low thermal conductivity (6.7 W/mK). Heat builds up at the cutting edge instead of spreading through the part. This means you need slow speeds, sharp carbide tools, heavy coolant, and rigid setups. RivCut has the tooling and experience to machine Ti-6Al-4V to tight tolerances.
Ti-6Al-4V Material Properties
Here are the key numbers you need when designing with titanium Ti-6Al-4V.
| Property | Value | Notes |
|---|---|---|
| Tensile Strength | 130 ksi (895 MPa) | Mill annealed condition |
| Yield Strength | 120 ksi (828 MPa) | 0.2% offset |
| Elongation | 14% | Good ductility for titanium |
| Hardness | Rockwell C36 | Comparable to heat-treated steel |
| Density | 0.160 lb/in³ (4.43 g/cm³) | 45% lighter than steel |
| Thermal Conductivity | 6.7 W/mK | Very low — causes heat buildup when machining |
| Max Service Temp | 600°F (315°C) continuous | Short-term up to 800°F |
| Composition | 6% Al, 4% V, balance Ti | Alpha-beta alloy |
| Corrosion Resistance | Excellent | Immune to seawater, body fluids, most acids |
| Biocompatibility | FDA approved | Used in implants and surgical tools |
Titanium Grades: Ti-6Al-4V vs Other Options
Ti-6Al-4V is not the only titanium grade. Here is how it compares to other common titanium alloys.
| Grade | Ti-6Al-4V (Grade 5) | Grade 2 CP | Ti-6Al-4V ELI (Grade 23) |
|---|---|---|---|
| Tensile Strength | 130 ksi | 50 ksi | 120 ksi |
| Yield Strength | 120 ksi | 40 ksi | 110 ksi |
| Density | 0.160 lb/in³ | 0.163 lb/in³ | 0.160 lb/in³ |
| Machinability | Difficult | Moderate | Difficult |
| Corrosion | Excellent | Excellent | Excellent |
| Biocompatible | Yes (FDA) | Yes | Yes — preferred for implants |
| Weldable | Yes (inert gas shield) | Yes | Yes |
| Best For | High-strength aerospace, medical, defense | Chemical processing, marine | Surgical implants, fatigue-critical |
| Cost | $$$$ | $$$ | $$$$$ |
Key takeaway: Ti-6Al-4V (Grade 5) is the best all-around titanium. It has the highest strength-to-weight ratio of any common metal. Grade 2 CP is easier to machine and cheaper but much weaker. Grade 23 (ELI) is the top choice for permanent implants because of its extra-low interstitial purity.
Ti-6Al-4V vs Other Metals
Not sure if titanium is right for your part? Here is how Ti-6Al-4V compares to the metals engineers consider most often.
| Property | Ti-6Al-4V | Al 7075-T6 | Steel 4340 | SS 17-4 PH |
|---|---|---|---|---|
| Tensile (ksi) | 130 | 83 | 145 | 150 |
| Density (lb/in³) | 0.160 | 0.101 | 0.284 | 0.282 |
| Strength/Weight | Best | Good | Low | Low |
| Corrosion | Excellent | Fair (anodize helps) | Poor (needs plating) | Good |
| Biocompatible | Yes | No | No | No |
| Max Temp | 600°F | 250°F | 800°F | 600°F |
| Machinability | Difficult | Excellent | Good | Moderate |
| Cost per Part | $200–$800 | $65–$200 | $100–$400 | $120–$450 |
Choose titanium Ti-6Al-4V when: You need the best strength-to-weight ratio. You need corrosion resistance without coatings. You need biocompatibility. You need to save weight in aerospace or racing. If weight does not matter and you just need strength, steel 4140 or steel 4340 costs much less.
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Upload CAD for Instant QuoteIndustries That Use Titanium Ti-6Al-4V
Ti-6Al-4V shows up wherever you need strength, low weight, and corrosion resistance. Here are the top industries.
Aerospace & Space
Structural brackets, engine mounts, fasteners, and landing gear parts in Ti-6Al-4V. 60% of all titanium goes to aerospace. Weight savings translate directly to fuel savings and payload capacity.
Medical Devices & Implants
Hip replacements, knee implants, bone screws, dental implants, spinal cages, and surgical instruments. FDA biocompatible. Resists body fluids. Bonds with living bone.
Defense & Military
Armor components, vehicle brackets, weapon system parts, and submarine fittings. Mil-spec Ti-6Al-4V per AMS 4928. Full traceability and material certs on every order.
Racing & Motorsport
Connecting rods, valves, springs, suspension links, and exhaust components. Weight savings at the wheel improve lap times. Ti-6Al-4V handles the heat and stress of racing.
Marine & Offshore
Propeller shafts, valve bodies, pump housings, and subsea connectors. Ti-6Al-4V is immune to seawater corrosion. No coatings needed. Parts last decades in salt water.
Oil & Gas
Downhole tools, drill collars, and wellhead components. Ti-6Al-4V resists sour gas (H2S), CO2, and chloride environments that destroy steel. Light weight reduces handling costs on rigs.
Design Tips for CNC Machining Titanium Ti-6Al-4V
Titanium is expensive to buy and slow to cut. These design tips keep your costs down and your parts good.
1 Keep Walls Thick
Thin walls flex during cutting, which causes chatter and bad surface finish. Minimum wall thickness for Ti-6Al-4V is 0.040 inches. 0.060 inches or more is ideal. Thicker walls let the machine run faster.
2 Add Inside Corner Radii
Sharp inside corners need small tools that cut slowly. A 0.030" radius or larger on inside corners lets the cutter move faster and lasts longer. This saves time and money on every titanium part.
3 Limit Pocket Depth
Deep pockets in titanium need long tools that chatter. Keep depth-to-width ratio under 4:1. A pocket that is 1 inch wide should be no more than 4 inches deep. Shallower pockets cut faster and cleaner.
4 Use Standard Tolerances Where Possible
Only call out ±0.001" on features that need it. Use ±0.005" everywhere else. Tight tolerances on titanium require slower feeds and more inspection passes. Each tight callout adds cost.
5 Minimize Material Removal
Titanium raw stock is expensive ($15–$50 per pound). Design your part close to the stock shape to waste less material. A near-net-shape design saves on both material cost and machining time.
Surface Finishes for Titanium Ti-6Al-4V
Titanium does not need a coating for corrosion resistance. But finishes can improve wear, appearance, and biocompatibility.
- As-machined: Clean tool marks, 125 Ra or better. Good for most aerospace and structural parts. No extra cost.
- Bead blasted: Uniform matte texture. Hides tool marks. Popular for visible parts and medical devices.
- Tumble deburring: Removes sharp edges. Safe to handle. Standard on all parts unless noted.
- Passivation: Acid bath removes surface contaminants. Boosts corrosion resistance. Common for medical and marine parts.
- Anodizing (Type II): Adds color (blue, purple, gold) and a thin oxide layer. Used for identification and light wear resistance.
- Anodizing (Type III): Thicker oxide layer for improved wear resistance on sliding surfaces.
- PVD coating (TiN, TiAlN): Adds a hard, wear-resistant layer. Gold or dark color. Used on cutting tools and high-wear parts.
- Mirror polish: Ultra-smooth finish for medical implants. Reduces bacterial adhesion. Improves biocompatibility.
Tolerances for CNC Machined Titanium Ti-6Al-4V
Titanium holds tight tolerances when machined correctly. Here is what RivCut can hold on your Ti-6Al-4V parts.
- General features: ±0.005" (±0.127 mm)
- Precision features: ±0.001" (±0.025 mm)
- Critical features: ±0.0005" (±0.013 mm) on request
- Surface finish: 32–125 Ra standard, 16 Ra or better on request
- Flatness: 0.001" per inch on ground surfaces
- Thread tolerances: Class 2A/2B standard, Class 3A/3B on request
Every titanium part is inspected with calibrated calipers, micrometers, and pin gauges. CMM inspection with a full dimensional report is available on request.
See Your Exact Price for Titanium Parts
Upload your CAD file and get real pricing with material, finish, and lead time options. Ti-6Al-4V parts typically cost $200–$800.
Upload CAD for Instant QuoteWhy RivCut for Titanium Ti-6Al-4V Machining
Titanium is not a material you want to trust to just any shop. Here is what makes RivCut different.
- Titanium experience. We machine Ti-6Al-4V every week. Our team knows the speeds, feeds, and tooling that produce good parts without burning tools or distorting features.
- Sharp carbide tooling. We use fresh carbide inserts and end mills designed for titanium. Dull tools cause work hardening and bad surface finish. We change tools before that happens.
- Heavy coolant. High-pressure flood coolant keeps the cutting zone cool. This extends tool life and prevents the heat damage that ruins titanium parts.
- Rigid setups. Titanium needs rigid fixturing to avoid chatter. We use solid vises, custom fixtures, and minimal stick-out to keep vibration low.
- 100% made in USA. Every titanium part is machined in our facility in Union City, California. No overseas outsourcing. Full traceability.
- Material certs on every order. We provide mill test reports (MTRs) and certificates of conformance for all Ti-6Al-4V orders. Required for aerospace and medical applications.
The RivCut Guarantee
If your titanium parts do not match your drawing, we remake them at no charge. Every dimension on your print is a promise we make. We back that promise with calibrated inspection equipment and a team that takes tolerance seriously.
Related Tools & Articles
Titanium Ti-6Al-4V CNC Machining: Common Questions
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