Laser cut Grade 5 Titanium sheet metal parts

Grade 5 Titanium FAQs and Design Considerations

Key Takeaways for Grade 5 Titanium (Ti-6Al-4V)

• Exceptional strength-to-weight ratio: ~130 ksi tensile strength while weighing ~40% less than steel.
• Highly corrosion resistant: Performs reliably in seawater, chlorides, and harsh industrial environments.
• Versatile applications: Aerospace, medical implants, marine, motorsports, and high-performance industrial parts.
• Best cut by waterjet: Maintains ±.009″ tolerances without heat distortion at SendCutSend.
• Forming and welding possible with care: Cold forming is limited; welding requires inert gas shielding to prevent contamination.

What is Grade 5 Titanium?

Grade 5 Titanium, also known as Ti-6Al-4V, is an alpha-beta titanium alloy containing 6% aluminum and 4% vanadium. This alloy balances high strength with good corrosion resistance and moderate formability, making it the workhorse of titanium alloys. Because of its performance, it accounts for the majority of titanium used in aerospace and industrial applications.

What are the physical and mechanical properties of Grade 5 Titanium?

Grade 5 Titanium combines low density with high tensile strength, typically around 130 ksi (900 MPa), while being about 40% lighter than steel. Key properties include:

• Density: 4.43 g/cm³ (about 56% the weight of steel)
• Tensile strength: ~130 ksi (900 MPa)
• Yield strength: ~120 ksi (828 MPa)
• Modulus of elasticity: ~16.5 Msi (114 GPa)
• Corrosion resistance: Excellent in many environments, especially chlorides and seawater
• Service temperature: Maintains strength up to ~600°F (316°C)

These numbers make it ideal where weight savings are as important as strength.

What industries and applications use Grade 5 Titanium?

Grade 5 Titanium is used everywhere weight, strength, and corrosion resistance must work together. Common applications include:

• Aerospace: airframes, engine components, landing gear
• Medical: surgical implants, bone screws, dental fixtures
• Marine: propeller shafts, fasteners, offshore equipment
• Motorsports: connecting rods, valves, high-performance fasteners
• Industrial: chemical processing equipment, power generation parts

For more examples of how different materials fit into specific projects, see our Material Catalog.

How does Grade 5 Titanium compare to commercially pure titanium (Grades 1–4)?

Grade 5 Titanium is much stronger than commercially pure titanium but has slightly less ductility and formability.

• Grades 1–4 (CP titanium): Excellent corrosion resistance and formability, but lower strength.
• Grade 5 (Ti-6Al-4V): Up to 3x stronger than CP titanium while still maintaining solid corrosion resistance.

If your design demands maximum strength in titanium, Grade 5 is the go-to choice. If you need maximum formability or weldability, SendCutSend’s Grade 2 titanium may be more suitable.

How does Grade 5 Titanium compare to aluminum, stainless steel, or Inconel?

Compared to aluminum, Grade 5 Titanium is stronger but heavier. Compared to stainless steel, it’s lighter with equal or better strength. Against Inconel, it offers weight savings at lower temperatures.

• Aluminum alloys: lighter and easier to machine, but weaker and less heat resistant.
• Stainless steel: strong and corrosion-resistant, but much heavier.
• Inconel: exceptional high-temperature performance, but heavier and more expensive.

If your project demands the highest strength-to-weight ratio, titanium usually wins. For a broader look at metals, check our Metal Comparison Guides.

Is Grade 5 Titanium biocompatible?

Yes, Grade 5 Titanium is highly biocompatible and is widely used in medical implants. Its ability to integrate with bone (osseointegration) makes it ideal for surgical hardware, dental implants, and orthopedic devices. The combination of corrosion resistance and biological compatibility ensures long service life inside the human body.

Can Grade 5 Titanium be laser cut, waterjet cut, or CNC routed?

Grade 5 Titanium is best cut with a laser for precision and to avoid heat-affected zones. At SendCutSend, we use high powered lasers to maintain tight tolerances and edge quality on titanium. This method achieves a ±.005″ tolerance and allows clean, consistent edges across a range of thicknesses. Explore our Design Guidelines to make sure your part geometry is optimized for waterjet cutting.

With laser cutting, tolerances on Grade 5 Titanium are typically ±.005″.

• Edge quality: Clean and precise with a smooth finish typical of high-powered laser cutting.
• Surface finish: Ships with the original mill finish; light scratches or discoloration may be present from handling and processing.
• Post-processing: Additional finishing options (like anodizing or powder coating available on other metals) may not apply directly to titanium, so designs should account for as-cut surfaces.

For exact details on tolerances, hole sizes, and minimum features, check the Titanium Material Specifications

Can Grade 5 Titanium be welded or joined?

Yes, Grade 5 Titanium can be welded, but it requires careful shielding to prevent contamination.

• GTAW (TIG) welding is most common, using inert gas shielding.
• Contamination from oxygen or nitrogen during welding will make the weld brittle.
• Filler metals such as ELI Grade 23 titanium are often used.

For most laser cut parts, mechanical fasteners are more common than welding, unless you have the expertise and equipment for titanium welding.

Can Grade 5 Titanium be bent or formed?

Yes, but with limitations: Grade 5 Titanium is less formable than pure titanium grades.

• Cold forming is possible in thin gauges, but springback is significant.
• For thicker sections, hot forming at elevated temperatures is often required.

At this time, SendCutSend does not offer bending on Grade 5 titanium. 

How does Grade 5 Titanium perform in fatigue, corrosion resistance, and long-term durability?

Grade 5 Titanium offers excellent fatigue resistance, corrosion resistance, and performance in extreme environments.

• Corrosion: Resists seawater, chlorides, and most industrial chemicals.
• Fatigue: Strong fatigue strength, especially when surface finish is controlled.
• Durability: Retains mechanical strength over long service cycles and in harsh environments.

This combination is why it’s the alloy of choice for aerospace and medical parts that must last for decades.

Design Takeaway

Grade 5 Titanium is the ultimate balance of strength, weight savings, and corrosion resistance, making it indispensable for aerospace, medical, and performance engineering. With SendCutSend’s laser cutting services, you can expect precision, clean edges, and fast turnaround on titanium parts in thicknesses up to 0.250″. If you’re ready to get started, upload your design today and explore our Material Catalog to compare titanium to other options.