Copper, sand, alumide… we have already discussed many materials used in additive manufacturing. Today, we are focusing on titanium. It is a transition metal that is never found in its pure form in nature. To extract it, minerals such as rutile (TiO2) and ilmenite (FeTiO3) go through complex processing.
This process produces pure titanium, but it remains energy-intensive. The metal produced generally achieves a purity of 99.9%, often alloyed with other metals to create higher-performance alloys. Thanks to its characteristics, the material has become a material of choice for additive manufacturing in fields like medicine, aerospace, and automotive. So, what are its advantages and characteristics? What 3D printing technologies can be used?
Photo credit: Freepik
What Are the Characteristics of Titanium?
Titanium, symbolized by Ti and with atomic number 22, is a material valued for its practical and versatile characteristics. It is distinguished by its lightness, strength, low toxicity, and high corrosion resistance, making it suitable for many applications. Furthermore, with a strength close to that of steel but a weight reduced by about 40%, it is particularly useful for manufacturing parts that are both lightweight and durable. Titanium is also resistant to salt water, chemicals, and wear, making it an ideal material for extreme environments. In addition to its mechanical properties, it has good thermal qualities, being able to withstand high temperatures of up to 600°C. Conversely, it remains stable even at very cold temperatures.
This material is difficult to machine, particularly due to its low thermal conductivity. During machining, as with CNC machines, most of the heat produced is retained by the machine, which can lead to rapid wear. In addition, machining often generates a lot of waste due to the removal of material. Faced with these issues, many companies are turning to more efficient methods of producing titanium parts. Metal 3D printing has therefore emerged as a promising solution.
Photo credit: AM Material
The Different Titanium Alloys for 3D Printing
As explained above, titanium is often used in alloy form in 3D printing, although it can also be extracted in its pure form for specific applications, such as in the medical sector, due to its biocompatibility. Several titanium alloys are used in 3D printing, the most common being Ti6Al-4V grade 5 (Ti64), a mixture of titanium, aluminum, and vanadium, valued for its heat and corrosion resistance. Other alloys include Ti6Al-4V grade 23, suitable for medical prostheses and implants, and Titanium Beta 21S, which is stronger and more resistant to oxidation and is used in orthopedic implants and aerospace engines. Cp-Ti (pure titanium) is also used in the medical field due to its compatibility with the human body. Finally, the TA15 alloy, composed of titanium, aluminum, and zirconium, is valued for manufacturing high-temperature resistant parts in aeronautics and engines.
Titanium alloys are preferred over pure titanium in the field of 3D printing because of their adaptability to complex applications. Although pure titanium is known for its lightness, corrosion resistance, and biocompatibility, it has certain limitations that sometimes make it less effective. Its toughness, hardness, and fatigue resistance are relatively low, which can be problematic for applications requiring materials capable of withstanding high loads and repeated stress.
Photo credit: Materialise
What 3D Printing Technologies Are Used?
In 3D printing, titanium is generally used in the form of metal powder or wire, depending on the technique chosen. Several technologies can be used to print with titanium, offering various solutions for manufacturing parts. One of the most common is directed energy deposition (DED). In this process, titanium powder or wire is deposited and then melted using an energy source, such as a laser. Another popular method is laser powder bed fusion (L-PBF), also known as DMLS or SLM. This technique uses a laser to melt metal powder particles, layer by layer, creating high-precision titanium parts, such as those made from Ti6Al4V alloy.
Electron beam melting (EBM) is also used to print titanium. It works differently from laser printing, using an electron beam in a vacuum environment, and is particularly suitable for manufacturing titanium parts that require high strength, such as those used in aerospace. Finally, binder jetting is another method where titanium powder is bound with a binder before being solidified by a sintering process.
Although very promising, 3D printing with titanium presents several challenges that are important to mention. First, production costs are high due to the price of its alloys, which are more expensive than other materials used for additive manufacturing. These costs are also due to the complexity of the printing process and the post-processing requirements for the parts. In addition, there are fewer titanium alloys available for 3D printing than other metals, which can complicate sourcing and increase costs. Finally, after printing, titanium parts often require careful post-processing, such as support removal, heat treatment, and polishing, to achieve the desired quality. These additional steps not only increase production time but also costs.
What Are the Applications for Titanium 3D Printing?
In the aerospace industry, titanium 3D printing has become established for the manufacture of key components, including turbine blades, supports, and structural parts. This metal is prized for its unique combination of lightness, strength, and resistance to extreme temperatures. In the medical field, the material has long been used for its biocompatible properties and corrosion resistance. From prosthetics to customized implants, this technology has transformed the medical sector by offering better results and reducing surgical time, as demonstrated by the examples of implants produced by Amnovis.
Titanium implants produced by Amnovis (Photo credit: Amnovis)
The automotive industry is also increasingly adopting 3D printing of titanium to reduce vehicle weight and improve fuel efficiency. This technology is used to manufacture engine components, exhaust systems, suspension parts, and even chassis parts. Finally, it is also spreading to other industrial sectors, such as tooling, jigs, and fasteners. This is because it allows the production of complex tools and structures tailored to specific needs.
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*Cover Photo Credit: Materialise