Titanium vs Aluminum: Which Metal Should You Choose for 3D Printing?

Metal is currently one of the most sought-after materials in additive manufacturing processes. Not surprisingly, its excellent properties make it the ideal choice for the most demanding applications in terms of performance and strength. In this article, we will focus on two of the main metals used in 3D printing: titanium and aluminum. These are mainly used for processes such as laser powder bed fusion (L-PBF) or directed energy deposition (DED). They are mainly available for 3D printers in powder form, especially in industrial environments. We will compare their similarities and differences, in order to better understand their properties and applications, and the advantages they offer in this manufacturing process.

Production and Characteristics of Titanium vs Aluminum

Titanium

Titanium is a material that does not occur in nature as an element and must instead be extracted from minerals such as rutile (TiO2) or ilmenite (FeTiO3). The extraction of pure titanium is a complex process that involves several steps. The most widely used method for the production of pure titanium is the Kroll method, developed by the American chemist William J. Kroll in 1940. This method involves the reduction of titanium dioxide (TiO2) with chlorine gas (Cl2) to produce titanium tetrachloride (TiCl4), which is then reduced with magnesium (Mg). Although the Kroll method is effective in producing pure titanium, it is an expensive process that requires a large amount of energy. In addition, the high reactivity of titanium makes it difficult to obtain as a pure metal, so much so that a sample with a purity of 99.9% is considered commercially pure titanium. Therefore, it is normally used in combination with other elements to form an alloy.

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Titanium has many properties that make it very versatile and useful in a number of sectors. As previously explained, it is often used in alloy form, but pure extracted titanium is used in certain applications, such as in the medical industry, due to its high biocompatibility. Its main characteristics are high mechanical strength, low density, excellent corrosion resistance and high rigidity.