Comparison analysis of titanium alloy

Ti6Al4V produced by metallurgical and 3D

printing method
Cite as: AIP Conference Proceedings 2077, 020025 (2019); https://doi.org/10.1063/1.5091886
Published Online: 21 February 2019

Karolina Karolewska, and Bogdan Ligaj

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AIP Conference Proceedings 2077, 020025 (2019); https://doi.org/10.1063/1.5091886 2077, 020025

© 2019 Author(s).
 Comparison Analysis of Titanium Alloy Ti6Al4V Produced
by Metallurgical and 3D Printing Method
Karolina Karolewska1, a) and Bogdan Ligaj1, b)
1
UTP University of Science and Technology in Bydgoszcz, Faculty of Mechanical Engineering, Al. Prof. S.
Kaliskiego 7, 85-796 Bydgoszcz, Poland
a)
Corresponding author: karolina.karolewska@utp.edu.pl
b)
bogdan.ligaj@utp.edu.pl

Abstract. 3D printing with the use of powdered metals is more and more commonly used, and its technologies as SLM,
SLS or LMD, have developed strongly in the last few years. AM technologies allow to the production of complicated
elements that are difficult to produce in another process. Additive manufacturing is increasingly used in the automotive,
aerospace and biomedical industries. The most commonly used material in these areas is titanium. Titanium alloy
Ti6Al4V is superlative for a machine elements requiring high strength. It is characterized by high mechanical properties,
low density, high corrosion resistance and biocompatibility with human tissue. For this reason, this material is excellent
for the production of biomedical implants The aim of the paper is to compare the properties of titanium alloy Ti6Al4V
under static loading conditions for samples made by 3D printing and metallurgical method. On the basis of literature
analysis, the results of experimental tests of samples made by use of additive manufacturing method in SLM technology
were presented.

INTRODUCTION

Application and Properties of Titanium Alloy

Despite the high costs compared to other materials, titanium alloys are widely used in the aerospace industry,
medicine as well as in motorsports. Ti6Al4V material is the most frequently tested alloy for medical applications. In
medicine, this material is used to produce implants replacing skeletal parts. The use of titanium in this area is due to
its biocompatibility with human tissue, through the rapid formation of a thin layer of oxygen on the surface of the
material and low weight and corrosion resistance [2]. In addition to these properties, implants have to be
characterized by high strength and hardness, as well as high plasticity and long fatigue life. The Young's modulus is
also important, which is 110 GPa for titanium. This means that the element made of titanium is characterized by
greater stiffness compared to human bones, where their Young's modulus varies from 2 GPa to 20 GPa. Implant
made of titanium takes over bone loads. In aerospace industry, titanium is used to produce fuselage stiffener,
undercarriage or turbines stiffen. Ti6Al4V is a frequently chosen material due to the lower mass compared to
structural steels, resistance to temperatures occurring in flight, resistance to corrosion, as well as the possibility of
joining titanium with composite materials [11].

TABLE 1. Mechanical properties of TI6Al4V produced according to the standard PN-EN 4267.

Mechanical properties
Material tensile strength Su 1013 MPa
Yield point of material Sy0,2 927 MPa
Elongation A 19.5 %
Necking Z 52%

Scientific Session on Applied Mechanics X

AIP Conf. Proc. 2077, 020025-1–020025-8; https://doi.org/10.1063/1.5091886
Published by AIP Publishing. 978-0-7354-1805-9/$30.00

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 Tables 1 and 2 present the mechanical properties of Ti6Al4V titanium alloy. Table 1 shows the properties of
titanium in the form of a drawn rod according to standard PN-EN 4267. Table 2 shows the mechanical properties of
Ti6Al4V titanium metallic powder adapted for 3D printing.

TABLE 2. Mechanical properties of TI6Al4V powder presented by EOS according to standard ASTM F1472.

Mechanical properties
Material tensile strength Su 1055 MPa
Yield point of material Sy0,2 945 MPa
Elongation A 13 %
Necking Z >25 %

The aim of the work is to compare the properties of Ti6Al4V titanium alloy under static loading conditions for
samples made by 3D printing and metallurgical method.
The scope of work includes the presentation and comparison of Ti6Al4V alloy material properties under the
static load conditions published in the literature.

PRODUCTION METHODS OF TITANIUM STRUCTURAL ELEMENTS

SLM 3D Printing Method

The advantage of 3D printing is the ability to produce elements of any shape, which is often difficult or
impossible by use of classic manufacturing techniques. The 3D printing market among metals is dominated by three
technologies, i.e. LMD (Laser Metal Deposition), SLM (Selective Laser Melting), SLS (Selective Laser Sintering).

Laser Scanner Laser Scanner

Metal Loose Metal Loose Melted

powder powder powder powder powder

Movable Movable
platform platform
(a) (b)
Laser Scanner Laser Scanner

Metal
powder

Movable
platform Camera
(c) (d)

FIGURE 1. SLM method production process: (a) distribution of metal powder, (b) powder selective melting, (c) lowering
the work platform and metal powder distribution, (d) creating next layers to form the entire element [17].

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 The SLM method uses a laser to melt metallic powder layers. The difference between SLM technology and
LMD lies in the way the material is fed. The SLM method consists in spreading metallic powder on a movable
platform (Fig. 1a), on which a laser beam heats particles of metal powder in specific places causing their melting
(Fig. 1b). Further the mobile platform is lowered and a another layer of powder is applied to the melted layer (Fig.
1c). All over again the powder melting process is carried out. These operations are repeated until the entire element
is created (Fig. 1d). Removal of supporting structures is the sequent stage in the process of producing a detail by the
3D printing method. After that, the element is heat treated and the supports are removed. The manufacturing process
of the structural element is carried out on the basis of a control program developed for the 3D model.
The difference between the SLM and SLS process depends on using the sintering process in the first one, while
the second method is based on melting. Sintering processes do not melt the powder completely, but heat it up to the
moment where its particles can merge together at the molecular level. During the laser melting, a fully molten
powder can be obtained - into a homogeneous part.
The 3D Printers based on SLS or SLM methods are able to both sinter and melt the powder, depending on the
process settings and the type of laser. According to the laser settings and its type, the following binding mechanisms
can be achieved: solid phase sintering, chemical bonding, liquid phase sintering, partial melting and full melting.

Metallurgical Process of Titanium rod Production

For the production of metallic titanium, the technology based on the Kroll process is commonly used, which
practically supplanted the Hunter process. In this process, titanium is obtained from ores contain titanium dioxide or
from titanium-rich slag produced in the metallurgical processing of ilmenite ore. Then TiCl4 titanium tetrachloride
is produced. In the Kroll process, titanium tetrachloride is reduced by means of molten magnesium under inert gas to
produce pure metallic titanium and a metallic titanium sponge. This reaction takes place in a reaction tank, which is
made of stainless steel or carbon steel. The reactor is firstly supplied with magnesium without containing oxides and
secondly the argon gas is provided. After the magnesium has been melted by external heating, titanium tetrachloride
is carefully introduced into the reactor. The temperature range is from 850 to 950 oC. Subsequently, purification of
titanium occurs during the iodide process. The purified titanium is melted in a plasma, electron-insulated, arcing or
induction furnace. The titanium melting temperature is 1668 ° C.
The titanium rod manufacturing processes are drawing and rolling. Drawing is a process of plastic forming of a
cold metal, in which the material being processed is moved through a suitably shaped hole of a special tool. In the
process of drawing the products in the form of rods or wires are obtained and characterized by precise cross-
sectional dimensions, a smooth bright surface and specific mechanical properties that can only be obtained with this
method of fabrication. As a result of drawing, the material geometrical and mechanical features are changed. The
transverse dimensions are reduced and the length increases, without changing the volume. Through the plastic
deformation in the draw plate, increase the material strength properties and decrease its plastic properties.
Other process of rod forming is hot rolling. This operation transform the size, shape and metallurgical properties
of the raw material by repeated metal (heated to a temperature 1050 – 1300 ̊C) crushing between rolls. In hot rolling
usually the following technological operations take place: preparation of the charge consisting of flame cleaning,
grinding, heating to the rolling temperature, descaling. Then the pre-rolling process (reduction of width, rolling to
the final dimension and properties) and finishing (edge trimming, longitudinal and transverse cutting).

MECHANICAL PROPERTIES TESTING RESULTS

Test Samples Made in SLM Technology

On figure 2 is presented a sample with its geometrical dimensions for static tests. Those specimens were used by
the authors in the papers [2, 3, 4]. In each article, the SLM printing method was used to produce the test sample. The
elements were made on the 3DSystem ProX 300 printer. In the work [4] on the basis of strength tests authors
obtained results of the Young's modulus E = 112.7 GPa, yield stress Sy0,2 = 1022,2 MPa, material strength Su =
1092,4 MPa and elongation A = 16.47%. In paper [2, 3] the authors presented the following results: Young's
modulus E = 113 GPa, yield point of material Sy0,2 = 1015 MPa, material tensile strength Su = 1090 MPa and
elongation A = 10%.

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 FIGURE 2 . Sample for static tests used in papers [2,3,4].

In the paper [5], flat samples showed in Figure 3 were printed on the MTT 250 machine. The specimens were
used for static tests. The authors do not give geometrical dimensions of the sample. The elements were made along
the Z axis of the printing direction and were characterized by the following strength parameters: yield point of
material Sy0,2 = 910 MPa, material tensile strength Su = 1035 MPa and elongation A = 3.3%.

FIGURE 3 . Sample for static tests used in paper [5].

In the article [6] standard samples for static tests were used. The test samples are shown in Figure 4. The authors
do not give geometrical dimensions of the tested elements. The samples were printed on an EOSINT M270 printer.
The building direction was coaxial with the Z axis. The following values of mechanical properties of the material
were obtained: yield point of material Sy0,2 = 952 MPa, material tensile strength Su = 1195 MPa and elongation A =
7.4%.

FIGURE 4 . Sample for static tests used in paper [6].

Publication [7] presents the results of static tests of cube-shaped samples with dimensions 64x64x64 mm. The
samples were printed on an EOSINT M 280 machine. The direction of printing of samples was consistent with the Z
axis of the coordinate system. The elements were printed for two different laser powers: 280 W and 340 W, as well
as two other applied powder thicknesses of 30 and 60 μm. For the 280 W laser power and the thickness of the
powder layer 30 μm, the yield point of material of Sy0,2 = 1161 MPa, material tensile strength S u = 1237 MPa and the
elongation A = 7.6% were obtained. However, for the 340 W laser power and the layer thickness of 60 μm, the yield
point of material was S y0,2 = 1151 MPa, material tensile strength S u = 1222 MPa and the elongation A = 9.8%.
The paper [12] presents the results of tests of samples made of Ti6Al4V. The samples were produced according
to the dimensions, which are shown in Figure 5. The specimens building direction consistent with the axis Z of the
coordinate system. On the basis of the static tensile tests, the following results were obtained: yield point of material
Sy0,2 = 1225.7 MPa, material tensile strength Su = 1360 MPa and elongation A = 3.1%.

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 FIGURE 5 . Sample for static tests used in paper [12].

In the article [13] the results of static tests of the sample shown in Figure 6 are presented. The samples were
produced by the use of SLM method on an EOS M270 printer. The laser power was 170 W and the thickness of
powder applied layer was 30 μm. In a static tensile test, the samples whose vertical direction was vertical (along the
Z axis) reached the values of the following parameters: yield point of material Sy0,2 = 1143 MPa, material tensile
strength Su = 1219 MPa and elongation A = 4.89%. The authors did not provide geometrical features of the
researched elements.

FIGURE 6. Sample statically tested used in article [13].

In the paper [16] can be found results from static tensile tests. The research were carried out on titanium samples
made in SLM technology. The test elements showed in Figure 6 were printed on the EOSINT M280 with the laser
power set at 170 W and the thickness of the spreading powder layer 30 μm. The direction of printing was the vertical
direction along the Z axis. As a result of the tests, the following values were obtained: yield point of material Sy0,2 =
1084 MPa, material tensile strength Su = 1262 MPa and elongation A = 6.1%.

Test Samples Made of Rod

The presented section describes the mechanical properties of Ti-6Al-4V made of hot-rolled bars.
In the paper [1] the samples for static tests were made of a Ti-6Al-4V rod with a diameter of 25 mm. The rod
was hot-rolled and annealed. The authors do not give the geometry of the test samples. The following results were
obtained from the tests: yield point S y0,2 = 911 MPa, material strength Su = 999 MPa and elongation A = 20%.
Article [14] presents a comparison of mechanical properties of titanium samples made in 3D printing technology
and samples made of rods. The samples with dimensions of 6x6x20 mm were cut out from a rod with a diameter of
70 mm and a length of 600 mm. On the basis of the static tests c, the following values of mechanical properties for
Ti-6Al-4V material were obtained: yield point of material Sy0,2 = 948 MPa, material tensile strength Su = 994 MPa
and elongation A = 21% and Young's modulus E = 105 GPa.
In the paper [10] the results of mechanical properties from static tests are presented. The samples were made of
rods according to the standard PN-EN ISO 26203-1. The yield point of material was between values of S y0,2 = 1003
÷ 1126 MPa, material tensile strength Su = 1035 ÷ 1107 MPa and elongation A = 19 ÷ 21%.

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 FIGURE 7 . Sample for static tests used in paper [9].

In the work [9] samples for static tests made of a rod are showed. The geometry of the samples is given in Figure
7. On the basis of a static tensile test following values were obtained: yield point of material S y0,2 = 915 MPa,
material tensile strength Su = 980 MPa and elongation A = 13% and Young's modulus E = 110 GPa.

SUMMARY
On the basis of literature the graph (Fig. 8) was prepared. The chart shows a obtained values comparison of yield
strength and tensile strength received under the conditions of titanium alloy Ti6Al4V for 3D printing (SLM) and
metallurgical method static tests. The graph shows that titanium elements produced by selective laser melting are
characterized by obtaining higher values of strength and yield point than elements made in a conventional method.
The maximum strength value for the 3D printing was 1360 MPa and the yield point was 1225.7 MPa [12]. The
highest values of these parameters for titanium made of rolled bars, found in [10] were Su = 1126 MPa S y0,2 = 1107
MPa. The graph shows a large spread of yield strength and strength results in 3D printing. It may be affected by
different geometries of the test samples as well as printing parameters. Because not all of the authors contain
important parameters such as: laser power, scanning speed, grain thickness, as well as the layer thickness of applied
metal powder. It cause that is difficult to compare the obtained results more precisely. Besides the above-described
factors, the porosity of the material structure and the direction of 3D printing have an influence on the values of the
obtained strength parameters. In not all articles the building direction of elements has been determined.

FIGURE 8. Comparison of yield point and strength obtained for Ti6Al4V

received by 3D and metallurgical printing.

Figure 9 shows a graph, which compare material elongation during static tests for components manufactured
using SLM technology and standard rods. The presented data show that samples made in 3D printing have lower
elongation values than those made from a rod. Based on the literature, it can be concluded that the higher the
strength parameters, the lower the elongation values.

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 FIGURE 9. Comparison of elongation results obtained for Ti6Al4V
received by 3D printing and metallurgical method.

As in the case of material tensile strength and yield point of material comparison, a large extent of elongation can
be seen in the graph for 3D printing method. This is influenced by the same factors as: the geometry of the test
samples, the laser power, the scanning speed, the grain thickness, the applied metal powder layer thickness, the
porosity of the material structure and the building direction of 3D printing.
The literature review allowed to develop our own experimental research program. The first stage is to assess the
strength under static loading conditions of samples made of Ti6Al4V made by DMLS printing technology and
pressed from a drawn bar. The geometrical dimensions of the test samples were determined according to the
standard PN-74 / H-043227. Physical form of samples is shown in Figure 10.

(a)

(b)
FIGURE 10. Samples for static properties tests made: (a) by the DMLS method, (b) from a drawn bar.

The results of our own research will be the subject of further publications related to 3D printing of Ti6Al4V
titanium and other alloys. The tests will also be carried out in the conditions of variable amplitude constant loads in
order to determine the cyclic properties of the material produced by the DMLS print method. The determine material
properties will be used to develop a two-parameter fatigue characteristic according to the models presented in [8,15].

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