A Guide on Titanium Fabrication Methods, Alloys,& Applications

Titanium fabrication

Although titanium is a tough metal with lower machinability and formability, it can still be fabricated into desired parts and products. You can use sheets, strips, rods, and pipes with both automated and manual sheet metal processing techniques. They can be cut, bent, punched, forged, and machined into the designed form.

As producing titanium components is challenging and requires several considerations, this article will discuss their various aspects to guide you through the fabrication process.

Let’s get started.

What Are the Properties of Titanium? 

Titanium Vs Steel & Aluminum Fabrication

Titanium(Ti) is a ductile, corrosion-resistant, and biocompatible metal with an excellent strength-to-weight ratio. Additionally, titanium alloys perform well at elevated temperatures without losing their original properties. 

When selecting titanium for your fabrication project, consider the following properties and ensure they align with your application requirements.

High Strength & Lightweight

Titanium exhibits high mechanical strength, almost twice that of steel for the same weight. So, it can be used for structural components in high-stress conditions. 

Ductility

Titanium shows good ductility, and it can be further increased by heating. Being ductile, titanium metal can be formed into desired shapes with bending, stretching, drawing, and other techniques. 

Corrosion Resistance

Titanium offers superior corrosion resistance compared to aluminium & steel. It produces a passive oxide film that reacts with moisture and protects the underlying structure from rust. 

Thermal Stability 

The melting point of titanium is above 1600°C, and its crystal structure shows the stable phases up to ~882°C, retaining the physical and mechanical properties. 

Biocomptiability 

Titanium is a bio-inert and non-allergenic metal, which remains stable in saline, blood plasma, and interstitial fluids. Thus, it is useful for various medical applications. 

Types of Raw Titanium Materials for Fabrication 

Mainly, three types of raw titanium materials are used for fabrication projects: flat sheets, tubes, and solid rods. Let’s further elaborate on them. 

Flat Titanium Sheets

Flat titanium sheets

These are the most common types of raw titanium material used in fabrication. They can be processed with cutting, bending, punching, stamping, and other precision metal fabrication techniques. Moreover, titanium sheet metal fabrication is also suitable for large-volume production. 

Titanium Tubes

Titanium tubes

Typically, titanium tubes are used for bending parts like exhaust system components, structural frames, and chemical processing lines. They are bent with die-press, rotatory, or other bending methods. Then, some other forming techniques are applied to give the final shape.

Titanium Solid Rods 

Titanium rods

Raw titanium rods are used to fabricate both large structural components and small industrial parts. They sustain high loads and extreme environmental conditions. For example, components of marine & offshore equipment, mounting features for aircraft parts, and chemical processing vessels. 

Which Titanium Alloys are Used in Fabrication? 

Alpha (α), beta(β), and alpha-beta(α+β) alloy grades of titanium are compatible for fabrication processes. They differ in alloying element and microstructure, thus providing slightly unique properties from each other. 

The table below outlines various titanium alloys for fabrication.

If you are interested in the fabrication of other metals besides titanium, read about the fabrication of steel, aluminium, and stainless steel by clicking on the corresponding links given below. 

Read more: 

• Steel fabrication
• Aluminum fabrication
• stainless steel fabrication

Methods for Titanium Fabrication

There are several methods used by manufacturers for titanium sheet metal fabrication services; you can use one or multiple methods to fabricate the desired parts. 

Let’s discuss titanium cutting, bending, forging, welding, and machining. 

Titanium Cutting

titanium laser cutting

It is the process of cutting, shaping, and sizing the titanium materials, often as a preparatory step for subsequent fabricating operations. Metal cutting methods you can use for titanium are laser cutting, waterjet cutting, and shear cutting. 

Titanium Bending 

titanium bending

Bending is one of the fundamental forming methods in sheet metal fabrication, including titanium. The process of titanium bending uses dies, presses, mandrels, and other tooling based on whether the raw material is in sheet, tube, or rod form. Although titanium needs a high forming force, it can be bent into a specific angle or curvature without any damage. 

Using the right bending force is critical; too high forces crack the titanium, whereas lower forces are not enough to deform.

• Cold Bending: It involves bending at room temperature and is suitable for thin titanium sheets, rods, and small tubes.
• Hot Bending: Thick and heavy titanium materials are heated before bending. It increases the ductility and makes the material easier to bend.  

Titanium Welding

Titanium laser welding

Welding joins multiple titanium components by establishing a strong and permanent joint. Sheet metal companies use Electron beam welding(EBW), TIG welding, or any other suitable technique. However, it is critical to consider the shielding from the environment, welding atmosphere, heat control, and joint design compatibility.

Titanium Hot Forging

titanium forging

Hot forging involves the use of high compressive forces on heated titanium, so the material flows inside the die cavity and forms the desired shape. It is suitable for components with minimal internal features. 

Titanium CNC Machining

titanium machining

CNC machining is often combined with forming methods in the titanium fabrication process. Fabricators use milling, turning, drilling, and many other machining methods to add specific features and correct the dimensions of fabricated items. Meanwhile, this titanium manufacturing method can shape the workpieces without any forming techniques. 

Work hardening and tool wear are two major issues in titanium machining, which can be addressed by the use of carbide tools and correct machining parameters.

Comparing The Costs of CNC Machined Aluminum, and Titanium Parts

The following are some common factors that contribute to the costs of cnc machined parts;

Material Cost:

Compared to steel and aluminum, titanium is much more costly. It has high extraction and refinement costs, which also add to this high cost. The fact that titanium is scarce also contributes to its high cost, thus being a high initial cost for any project. However, the advantages of titanium can offset the higher costs of the material since it is expensive. The material cost is a significant factor that affects the budgetary plan since it is a major component of the total cost. One has to bear this high base cost of titanium in mind when selecting it for use in a particular project.

Tooling and Equipment:

Machining titanium using CNC requires special tools and equipment that are more prone to wear than those used in other materials. This often requires replacement, which in turn increases the machining costs significantly. The longevity of the tools used is vital to guarantee the effectiveness and quality of the work. The cost of specialized tools is also high, and this is considered one of the factors that contribute to the total cost. More tool wear is not only a problem in terms of time but also money. High-quality machining processes often demand changes in tools.

Machining Speed:

Titanium has lower machinability, which implies that to get the right level of precision, slow machining speeds are required. These reduced speeds lead to a longer time to produce the same amount of output, which in turn leads to increased labor costs. Slow machining speeds slow down the overall production process, and thus, efficiency is affected. Complex processes require special attention regarding cost control, especially when it comes to time-consuming activities. The problems associated with low-speed machining of titanium have to be met with accuracy requirements. These slower speeds must be considered when setting the project deadlines, which means that the latter must be planned.

Tool Wear and Tool Life:

Titanium is a rigid material, and this increases the rate of tool wear; thus, the tools need to be replaced frequently. This leads to increased operational costs since the wear increases with the amount of time the equipment is used. Tool wear is another factor that is very sensitive as it affects the efficiency and the amount of money to be spent. Machining quality requires regular replacements of the tools, but this increases the expense. The rapid deterioration of tools disrupts the flow of machining and the general project time frame, which is why tool durability is an essential component of cost control.

Coolant and Lubrication:

Titanium is relatively hard to machine due to the high heat produced; therefore, adequate coolant and lubrication are necessary to avoid damaging the tools and the workpieces. These fluids form part of the cost of machining and, therefore, increase the price of the final product. Heat control is significant in ensuring accuracy and avoiding damaging the tools that are used in the process. The expenses of the coolants and lubricants also have to be considered as part of the total costs. Cooling is a critical element of the process since it minimizes operational risks and guarantees the production of high-quality parts.

Energy Consumption:

Titanium requires more energy to be machined because of its high melting point and inability to deform. This increases the energy consumption and, thus, the operating costs of the business. Machining efficiency is also a factor of energy consumption to ensure that the costs are well controlled. Energy requirements are also a function of the amount of power required to power the machinery used in titanium machining. They, thus, are a determinant of the cost of titanium machining. Energy control is critical in managing costs since it is a crucial factor in production.

Post-Processing:

Titanium components may also need further processing, such as heat treatment and surface treatment. These additional steps cost more than other materials that may not require further processing after they are cut to size. These are the comprehensive steps that are taken to guarantee high quality of titanium parts, but they contribute to the total project cost. The time and cost of post-processing must be managed effectively in order to sustain the project’s efficiency and productivity.

Scrap and Waste:

Machining of titanium can generate more scrap and waste because of the material’s relatively poor machinability. The level of waste must be kept to a minimum, which means that precision and a high level of control are required to reduce wastage, which is costly. The management of waste is another factor that needs to be worked on to ensure that there is minimum wastage of materials. High scrap rates significantly contribute to costs. Therefore, waste management is a critical component of cost management. Precision machining also minimizes wastage that is not required, hence improving costs.

Expertise and Skilled Labor:

Titanium requires a highly skilled operator who is well conversant with the material to be able to machine it. This specialization leads to high labor costs, which is a significant factor that affects the prices of the products. Machining titanium requires skilled labor so as to meet the required precision and quality of the final product. Hiring skilled employees improves the machining process; however, it affects the cost of the project. Experience and training are critical to the machining of titanium.

Quality Control and Inspection:

Titanium parts are usually susceptible and must be checked and tested very often. Sophisticated inspection tools and techniques help to maintain part quality but are costly. It is essential to ensure that quality control is done to the highest standards to ensure the best performance. Cost and quality are two critical factors in the machining of titanium. Strict measures are taken to avoid such problems in the future and guarantee the necessary quality of titanium parts. Implementing quality control measures increases confidence in the final product, hence the need to invest in it.

What is Titanium Heat Treatment and Why is It Important in Fabrication?

Heat treatment of titanium

Heat treatment is a process of controlled heating & cooling to alter the microstructure of the material, improving physical & mechanical characteristics. It is important in titanium fabrication for stress relief of fabricated items. 

Annealing heat treatment is used for titanium, which involves heating at high temperature and cooling down to room temperature at a slow rate. This method allows titanium to relief internal stress from metal forming operations and stablize the mechanical properties.

Surface Treatment and Finishing 

Often, the fabricated titanium part or product requires surface treatment & finishing to enhance the surface properties, aesthetic, and dimensional accuracy. Meanwhile, surface finishing improves the smoothness and aesthetic. 

You can apply any of the following surface treatments and finishing techniques to the titanium parts.

• Passivation: This surface treatment method uses chemicals to remove the metallic contaminants, organic residues, and surface oxides. 
• Surface Polishing: It is the process of removing minor material from the surface using a fine-grain abrasive wheel, which reduces the roughness significantly and creates a glossy finish.
• Bead or Sandblasting: Beads of zirconia alumina or other abrasive material are blasted over the titanium surface at high speed to clean and smooth the surface. 
• Anodizing: In this process, a hard protective layer of titanium oxide is created through electrolysis. Anodizing improves surface hardness and has an extensive color spectrum. 
• Plating: It refers to coating a metallic layer through electrolysis, useful for both corrosion protection and aesthetics. 
• Plasma Nitriding: This surface treatment method develops a titanium nitride layer by use of a vacuum & heated nitrogen-containing plasma chamber. It increases the surface hardness and corrosion resistance. 

Titanium in Pressure Vessel Fabrication

Especially, pressure vessels that need to withstand extreme stress, heat, and chemical exposures are made with titanium. For example,  chemical reactors, desalination plant components, and offshore gas systems.

Pressure vessels are typically made by forming titanium plates or sheets through rolling, forging, and bending, followed by precision welding under inert gas. Furthermore, fabricated pressure vessels are strengthened with a heat treatment process.

What are the Applications of Titanium Fabrication? Product Examples 

Fabricated titanium components 

Titanium fabrication products & components are ideal for applications where a high strength-to-weight ratio, fatigue resistance, corrosion resistance, and thermal stability are crucial for performance. 

Let’s look at the product examples of titanium fabrication across various industries, including automotive, marine hardware, aerospace, pipes & fittings, pressure vessels, industrial machinery, and chemical processing. 

• Automotive:  Exhaust headers, springs & retainers, suspension components, and fasteners for motorsport. 

• Marine Hardware: Thru-hull fittings, propeller shafts, in-ship tubing, seawater tubing, deck hardware, and offshore systems. 

• Aerospace: Aircraft fasteners, airframe brackets, compressor parts, and hydraulic actuator bodies. 

• Pipes & Fittings: Piping in harsh environments, like humid and underwater installations. E.g., flanges, pipe spools, and instrument tubing. 

• Pressure Vessels: High-pressure gas cylinders, aerospace gas tanks, industrial pressure, and autoclave liners. 

• Industrial Machinery: Pump shafts, mixing blades for slurries, tooling fixtures, valve seats, and guide rails.

• Chemical Processing: Reactor baffles & trays, distillation column internals, corrosion-resistant piping manifolds, and components of chlor-alkali hardware.

What Are the Common Challenges in Fabricating Titanium? 

The titanium fabrication challenges are associated with the process complexity, required equipment & tooling, and raw material cost.  

The list below outlines the common challenges in titanium fabrication. 

• Complexity: It is challenging to sequence the fabrication operations while making complex titanium components. 
• Titanium Cost: Although titanium has excellent properties for high-performance applications, it is an expensive engineering material. 
• Tool Wear: Titanium tends to stick with cutting tools during machining, which increases the tool wear. Therefore, you need a special coating on the cutting tool.

Summing Up

Titanium is a relatively challenging material to fabricate into desired parts & products, compared to other engineering materials like steel and aluminium. Therefore, you can shape different titanium alloys precisely with careful considerations and the use of appropriate equipment & tooling.

Furthermore, it is also important to choose an expert & experienced manufacturer for high-quality titanium parts, like  ProleanTech. We have our own in-house machine shop and fabrication facility with advanced equipment & systems. 

FAQs

Why is titanium so hard to weld?

Titanium reacts quickly with oxygen, nitrogen, and hydrogen at high temperatures, which makes it difficult to avoid contamination in joints. 

 What is the downside of titanium?

The main downside of titanium is its difficulty with machining and forming processes. Additionally, it is also a relatively expensive manufacturing material. 

 How is titanium made?

Titanium is produced in the form that we see in the market by extracting mineral ores like rutile or ilmenite through various metallurgical processes.