Titanium, a common choice for orthopedic implants

Manufacturers started to use titanium for orthopedic implants, as they recognized the natural properties this metal had to offer. It had an incredible strength-to-weight ratio, excellent corrosion resistance and, most importantly, it was 100% biocompatible.

It was soon discovered that titanium even promoted the osseointegration process, developing a physical bond with the bone (no additional adhesive substances necessary). Moreover, it was determined that titanium implants could withstand high energy forces (no breakage). They did not react to the environment in which they were placed and lasted for a long period of time (no replacement required in some cases).

Titanium is nowadays used not only for internal fixation but also for prosthetics, medical instruments and inner-body devices. There are certain alloys which are preferred for both medical and dental implants, such as Ti-6Al-4V and Ti-6Al-4V ELI. These are alpha-beta alloys, commonly alloyed with aluminum and vanadium. They offer a high level of fracture resistance, not to mention they facilitate osseointegration (faster recovery).

It is a well known fact that titanium is an inert metal, thanks to the protective oxide film that forms upon being exposed to oxygen (natural occurrence). The metal is resistant to damage caused by bodily fluids and tissues, which means it will not be rejected by our bodies.

For this reason, you will see titanium being used for cranial plates, elbow and knee joints and even ribs. Bone screws, staples and cables can be made from titanium. All orthopedic implants developed from titanium provide excellent support to broken bones, facilitating the fixation process.

New titanium alloy developed for orthopedic implants

Beta titanium alloys have long been in the spotlight with regard to orthopedic implants, as they have good formability and excellent mechanical properties. They have amazing corrosion resistance, as well as a high level of mechanical and fatigue resistance.

One of the main reasons for which beta titanium alloys are used for orthopedic implants is their low elastic modulus. Recently, a new beta alloy was developed for such applications – Ti-35Nb-7Zr-5Ta. This alloy was produced through powder metallurgy, having a porous structure and being a suitable choice for the successful osseointegration.

Titanium elastic nailing system for long bone fractures in children

The titanium elastic nailing system (TEN) is intended to fixate diaphyseal fractures of long bones. Such bones have a narrow medullary canal and it is important to be able to use an implant that is flexible. TEN is a preferred option, as it has a reduced risk of complications.

A major benefit of using the titanium elastic nailing system is the immediate post-operative stability. This allows for the early mobilization of the involved segment, with the patient returning to normal activities in a shorter period of time. Moreover, such orthopedic implants have a low complication rate, being a minimally-invasive procedure.

It can be used on pediatric fractures in children between 5 and 14 years of age. The system is safe and reliable, being recommended for long bones. The intervention has a reduced duration and the recovery is fast, with a good functional outcome.

Thanks to TEN, the patient can bear weight early on and heal rapidly, the bone growth being only minimally disturbed. It is also worth mentioning that the titanium elastic nailing system can be used in such fractures, regardless of their location or pattern.

Vertical expandable prosthetic titanium rib

The prosthetic titanium rib is an innovative device, designed to stabilize both the spine and ribs in children with deformities of the chest wall. The curved metal rod is meant to improve breathing, being recommended as a treatment for severe scoliosis as well. Medical specialists have also used the titanium rib in children who needed chest reconstruction after cancer surgery (involving the removal of several ribs).

Children diagnosed with the thoracic insufficiency syndrome can benefit from the prosthetic titanium rib as well. The device can straighten the spine and separate the ribs, thus allowing the lungs to expand more efficiently in the newly created space. Moreover, it can stabilize the diaphragm, the muscle used for breathing.

The prosthetic titanium rib is adjusted in accordance with each child and his/her necessities. It is important to understand that the device is expandable; as the child grows, new interventions will be performed to add length.

Titanium nanotubes for more efficient osseointegration

Titanium nanotubes can improve the osseointegration of orthopedic implants, reducing the risk of bacterial colonization at the same time. Given this discovery, researchers have enhanced titanium implant surfaces with titanium nanotubes.

Orthopedic implants treated with titanium dioxide nanotubes guarantee a more effective osseointegration. Thus, the bond between the implant and bone is strengthened. In patients who received such kind of implants, the early weight bearing is excellent.

Graphene-coated titanium alloys – more effective osteogenesis and osseointegration

The coating of titanium alloys with graphene can actually enhance their surface bioactivation, which will further support the effective osteogenesis and osseointegration processes. The graphene coating improves the biocompatibility of titanium alloys, promoting the regeneration of the bone tissue and improving the bone-implant bonding.

Graphene is an innovative nano-coating material, which can facilitate the biological activity of titanium alloys and promote the above-mentioned processes. Such orthopedic implants have a high mechanical strength and fracture toughness, being resistant to corrosion and 100% biocompatible.

Final word

In conclusion, titanium is an excellent choice for orthopedic implants, being strong, resistant to corrosion and biocompatible. Researchers are continuously working on developing innovative devices, with each of them targeting a subsequent need. In the future, titanium will be used even more often, as doctors are interested in orthopedic implants that can resist for longer periods of time, without being rejected by the body.

Commercially-pure titanium

Titanium, in its unalloyed form, is a lightweight and strong material. Its tensile strength is similar to the one of carbon steel, however its weight is half. Pure titanium is silver-colored, has a low density and a unique luster.

Titanium has excellent corrosion resistance, being the ideal choice for seawater applications (offshore and marine environments). The pure titanium wrought products are mainly used for their resistance to corrosion.

It is also worth mentioning that commercially-pure titanium can withstand the damage (corrosion) caused by other fluids, such as acid rain. For this reason, titanium is nowadays used innovatively for architectural applications. Titanium also has a high resistance to stress corrosion cracking, which makes it an even more interesting material to use.

From a green perspective, titanium is an environmentally-friendly material. Unlike other metals, it does not liberate toxic heavy metal ions (these occur through the corrosion process, which is not a problem with titanium). With regard to forming, titanium can be formed just as easily as stainless steel. Its thermal expansion and shrinkage are, however, higher than stainless steel.

In its pure form, titanium has four distinct grades, each with different properties to offer (corrosion resistance, formability/ductility, strength, etc.). For example, grade 1 titanium has the highest corrosion resistance and formability, but lower strength. Grade 4, by comparison, has the highest strength and only moderate formability.

Commercially-pure titanium is available in different forms, such as bars, cables, strands, coils and flat wire. It can be used for medical applications, including orthopedic implants, needles, sutures, dental implants and even eye glass frames. Titanium has a high strength-to-weight ratio, which means that it is highly resistant to damage and lightweight at the same time.

Titanium alloys

Titanium can be alloyed with different materials, such as aluminum and vanadium, the resulting alloys being used in the aerospace, chemical and energy fields. Other titanium alloys are made with molybdenum and iron, chromium, nickel, copper, cobalt. The mixture of titanium and various alloys results in increased tensile strength and toughness (even at extreme temperatures).

With their excellent mechanical properties, titanium alloys can be used for the most challenging applications. The components of gas turbine engines can be made with titanium alloys, as well as various airframe parts, for both commercial and military aircrafts.

Nuclear power plants and food processing plants rely on the use of titanium alloys. These are used for heat exchangers in oil refineries, marine components thanks to their high corrosion resistance and, given their biocompatibility, for medical prostheses.

Titanium is sometimes alloyed with palladium, the resulting alloy exhibiting improved resistance to corrosion and strength. Titanium-palladium alloys are used in applications that require excellent corrosion resistance. You will see them being used in chemical processing industries, as well as for storage applications.

Titanium alloys are suitable for environments in which corrosion is a challenge, where there is a permanent fluctuation between oxidizing and reducing. One of the most used titanium alloys is Ti-6Al-4V, which is an alpha-beta alloy. This alloy has a high level of tolerance, being suitable for a wide range of applications.

Alpha alloys contain neutral-alloying elements, as well as alpha stabilizers (aluminum, oxygen, etc.). These have a good strength and weldability, presenting oxidation resistance (even when used at elevated temperatures, this being the result of the aluminum content).

Both titanium and its alloys can be heat treated, in order to increase their overall strength, reduce the residual stress and even to optimize the fracture toughness. However, alpha alloys cannot be heat treated to enhance their mechanical properties, as they are single-phase alloys.

Near-alpha alloys contain a reduced amount of beta-phase stabilizers, which increase their overall ductility. The beta-phase stabilizers are added to a percentage of 1-2% (most commonly these are silicon, vanadium or molybdenum).
Alpha-beta alloys, as their name clearly suggests, are a combination of both beta and alpha stabilizers. These can be heat treated for added strength but it is worth mentioning that their formability will decrease in proportion to the newly-obtained strength (post-treatment).

Beta alloys have a high percentage of beta stabilizers, such as silicon, vanadium or molybdenum. These are treated with different solutions and aged, resulting in improved strength. Beta alloys have excellent formability and they can be easily welded. These are often seen in orthodontic applications, having replaced stainless steel.

Titanium or titanium alloys – selection for service

In deciding on the use of unalloyed commercially-pure titanium or one of its alloys, manufacturers will take into account basic factors such as strength and corrosion resistance. Mechanical properties, such as density, fatigue crack growth rate and fracture toughness will determine the alloy composition and the necessity for heat treatment.

Commercially-pure, unalloyed titanium is generally preferred for corrosion applications, as it as a lower strength. Such applications can include heat exchangers, tanks and reactor vessels, for various industries and fields, including power generation, chemical processing and desalination.

When it comes to high-performance applications, higher-strength titanium alloys are employed. These are used for the development of gas turbines and various aircraft structures, as well as submersibles and drilling equipment. Titanium alloys are nowadays used for the making of biomedical implants and bicycle parts (frames) as well.

Alloys such as Ti-6Al-4V and Ti-3Al-8V-6Cr-4Mo-4Zr are used for offshore drilling applications and geothermal piping. Other alloys, including Ti-6V-2Sn-2Zr-2Cr-2Mo+Si, Ti-10V-2Fe-3Al, Ti-6Al-2Sn-4Zr-2Mo+Si, can be employed for aerospace applications, as well as gas turbine engines.

Manufactures might decide to consider first corrosion resistance and not the strength or temperature resistance of a certain titanium alloy (corrosion resistance as major selection factor). When deciding whether a certain titanium alloy will be used for corrosion applications, economic considerations way a lot in the decision process.

The preference for titanium with regard to military applications is not something random. The metal maintains a high level of performance, even at elevated temperatures. Moreover, it has both the fatigue and fracture toughness required for such applications. Lightweight and strong, with excellent corrosion resistance, titanium is seen as a valuable resource in the military.

The high demand for titanium in the military field has contributed to the innovative research regarding new potential uses. It was important for the military industry to find a metal that can withstand extreme conditions, without its efficiency, strength of resistance being affected.

As the titanium extraction and purification processes became less complex, the metal was gradually preferred for various components (it replaced steel as the standard choice). Titanium is no longer as expensive as in the past and, as it becomes easily available, the military field increasingly relies on it.

Military uses of titanium

Titanium is nowadays used for the development of aircraft parts, as well as for missiles, armor plating and naval ships. Even spacecrafts have components from titanium, given its high versatility in different environments.
Apart from commercially-pure titanium, manufacturers rely on titanium alloys as well. They alloy titanium with aluminum and vanadium, developing landing gears, exhaust ducts and hydraulic systems. Recently, titanium has been alloyed with tungsten, the resulting mixture being used for tank armors (battlefield protection). Critical structural parts and firewalls can be made with titanium alloys.

It is true that titanium alloys are quite popular in the military field, including for various parts and hydraulic systems. Alpha alloys, however, are not used, as they cannot be heat treated and, thus, it is impossible to obtain the necessary mechanical properties. Alpha-beta alloys, on the other hand, can be heat treated, having both the necessary strength and ductility for various military applications.

Given the high resistance of titanium, it should come as no surprise that manufacturers are using the metal for the making of armor suits (enhanced protection against ballistic threats).

Every day, thanks to innovative research, titanium finds more and more uses in the military field. Apart from armor protection and aircraft structural components, it is employed for the making of battlefield tanks and missiles, as well as for other types of weaponry and piping (naval seawater).

The armor for both tanks and military personnel can be made with titanium as main constituent. Personal carriers and ordnance equipment, as well as armor plating, are made from titanium. This is because titanium has a reduced weight yet it is incredible strong, resisting ballistic attacks.

Titanium grades – military use

When it comes to armor applications, Ti-6A1-4V is commonly preferred, as it has the best ballistic performance to offer. Another alloy, Ti-6AL-4V ELI, is often employed for the development of aircraft turbines and other pieces of equipment operating in environments with incredibly high temperatures.

For ordnance components and frames, 6AL-6V-2Sn-Ti is preferred. This titanium alloy is sometimes used for the development of landing gears and rocket cases. Grade 5 titanium is employed for a wide range of military applications, exhibiting higher strength when heat treated.

Titanium composites, a recent discovery

In the past few decades, researchers have concentrated on the use of titanium composites, including in the military field. The composite has been developed from titanium and fiberglass, being used for the manufacturing of rotor blades (these are nowadays found in the Black Hawk helicopters).

Why are composites so often employed for military applications? The answer is simple. These titanium composites have a superior conductivity to offer, especially in comparison to carbon composites. Moreover, they guarantee a highly-effective galvanic and thermal expansion.

Use of titanium in the navy

Navy applications require a metal that can resist seawater damage, without its integrity being affected at all. Titanium, with its excellent corrosion resistance, represents a truly ideal choice. Thus, it is used for the development of equipment that frequently comes in contact with seawater.

Propeller shafts and underwater manipulators are made from titanium and its alloys. The same goes for rigging equipment, shipboard cooling systems and piping. The metal represents the first choice for the making of submarine ball valves and heat exchangers, as well as fire pumps and exhaust stack liners.

Before titanium became used on a large scale, the seawater piping damage was a constant problem. This deterioration was especially encountered in heat exchangers, requiring frequent replacements and repairs (higher service costs). In time, the copper-nickel pipes were replaced by those from titanium, with improved lifespan and reduced service costs.

Use of titanium in the Air Force

The military aircraft industry has relied on titanium for decades, especially for frames and bodes. Today, you will also see other aircraft components made from titanium or its alloys, including wind access panels, landing gears and brackets. It has been estimated that up to 25% of a military aircraft contains titanium (this percentage is higher than the one encountered in commercial airplanes).

The reason for which titanium is so popular in the military aerospace field has to do with great performance, especially with elevated temperatures (over 600ºC). Given such properties, titanium is nowadays used for the making of jet engine castings and compressor discs. While other metals would crack, suffering from fatigue at such temperatures, titanium can resist such high temperatures and maintain absolute best performance.

Use of titanium – oil & gas industry

In the oil industry, titanium is used for both exploration and production. You will also see titanium being used for construction, engineering and refining. Pipelines are nowadays built with titanium as main constituent and underwater operations rely on it, given its excellent resistance to corrosion (seawater, as we all know, is highly corrosive).

The different grades of titanium are employed for the development of heat exchangers (tube-in-shell, plate type), as well as pumps and valves. Data logging equipment, various fixtures and fittings, as well as tanker purge systems can be developed from titanium. Submersibles, which are used in underwater operations, and cathodic protection anodes complete the list of titanium applications.

In recent years, titanium has begun to be used for the making of downhole tubulars. These are components of oil and gas wells, requiring an excellent resistance to corrosion and amazing strength. Titanium is now used for HPHT well applications – high pressure high temperature – demonstrating not only resistance to corrosion but also to stress corrosion cracking.

Why is titanium the favorite?

As the interest in hydrocarbon reserves becomes more prominent, the wells for extraction are reaching deeper levels. This means that the equipment used must be able to resist higher temperatures, as well as a higher level of pressure and tensile loading. Titanium seems to be the correct response to all of these requirements.

The high levels of activity in the oil and gas industries have pushed the demand for titanium even further. Corrosion resistant alloys, such as the ones made with titanium, are especially used for tubular equipment.

The alpha-phase titanium alloys offer the highest resistance to corrosion but it is important to know that all titanium alloys can resist fluid damage (and especially the one caused by seawater). The corrosion resistance of titanium is ensured by the oxide layer present on the surface of the metal, which is also responsible for its added strength and stability.

Low-pressure seawater piping is made from titanium, as well as coiled tubing, bolts and various downhole tools. Drilling risers and riser taper joints are made from titanium and its alloys (different grades). In the future, manufacturers hope that the metal might be used for subsea piping.

Titanium, a versatile metal for the oil and gas industries

The oil and gas industries appreciate titanium for being a metal that is both versatile and valuable. Recognizing the incredible qualities of titanium, manufacturers have begun to add titanium to steel alloys. This increased not only the strength and density of the material, but also its corrosion resistance.

The titanium-steel alloy has a widespread use nowadays, especially for the lining of downhole tubing. Compressor parts are also made from high-strength titanium alloys. These are durable and guarantee a longer service life, in comparison to the parts that contained only steel alloys.

The fact that titanium is resistant to seawater is not news. However, it is worth mentioning that titanium presents excellent corrosion resistance to other environments as well, including those with carbon dioxide and hydrogen sulfide.

In the gas industry, it is a preferred choice, as it is capable of maintaining its strength at extremely low temperatures (used for the liquefaction of natural gas). The tubing of heat exchangers is made from titanium, these being used in liquefied natural gas plants. You will also see titanium being employed for the lining of pressurized vessels (such as those in LNG tankers).

Titanium in offshore applications

The offshore oil and gas industries rely heavily on titanium and its alloys for a wide range of applications. The metal is appreciated for its excellent corrosion resistance, not only in seawater but also in the petroleum refinery environment.

In the past few years, the titanium demand for offshore application has increased tremendously. This is especially seen in the Norwegian sector of the North Sea, where titanium and its alloys are used regularly. The use of titanium has eliminated the corrosion problem faced with steel (crevice corrosion in particular). Fire and service water piping, low-pressure ballast and various fittings are developed from titanium today.

Unlike some years ago, titanium has now a competitive and rather stable price. Given this stability, it should come as no surprise that it is used for the development of a wide range of products, including piping, fittings and various systems, all for offshore applications.

Cold bending is used for the making of titanium piping, as this method reduced a huge percentage of the welding work. As titanium pipes have a low weight, the installation process is facile and does not require more than one person. Moreover, the pipes made from titanium do not require to be painted. Shot blasting and the treatment of pipe surfaces (post-installation) are not required either.

Titanium pipes are also used for fire systems. Thin-wall welded titanium pipes comply with existent fire regulations, having passed fire tests as well. They have an unparalleled resistance to shock, as well as a high tolerance to damage. This means that they have the best chances for survival in case of various disasters, involving fires, explosions and so on.

On offshore platforms, titanium fire water systems are commonly used. The same goes for titanium pipework, valves and nozzles. Even deluge system detectors and sprinklers are made from titanium. High-pressure heat exchangers are developed from titanium alloys, most commonly from Ti-6A1-4V. These have a reduced weight and volume, offering a considerable advantage.

In short, titanium plays a well-deserved role in the oil and gas industries. It is especially appreciated for its strength-to-weight ratio and corrosion resistance, being suitable for seawater applications. The offshore industry relies heavily on the use of titanium and its alloys, whether for fire systems, heat exchangers or piping.

Designers from all over the world have chosen titanium for the creation of unique statement pieces. From a practical perspective, it is worth mentioning that titanium is an inert metal, which means it does not come into contact with the skin. For this reason, titanium jewelry is a suitable choice for those who suffer from allergies. Even body piercings are made nowadays from titanium, given such considerations (chemical inertness).

Titanium has a high resistance to corrosion, which means that it can be worn in otherwise corrosive environments (such as water – swimming pools). It can be alloyed with gold and, given the reduced percentage of titanium in this alloy, it is also marketed as 24-carat gold. In terms of hardness, the alloy can be compared to the 14-carat gold. However, when it comes to durability, it is more durable than the 24-carat gold (pure).

It is a well-known fact that titanium has a natural grey color. However, when it is anodized, it can turn into different colors. The various shades are dependent on the thickness of the surface oxide layer, the color being actually given by an optical interference.

The iridescent sheen is one of the main reasons for which titanium is so often preferred for high-end jewelry lines. The metal is light yet strong, and the spectrum of colors is indeed appreciated. Even though it is quite difficult to craft, designers rely on titanium to create lighter jewelry pieces (titanium is significantly lighter than gold).
It was at the end of the 1980s that titanium first began to be used by avant-garde jewelry designers. The metal presents a unique optical phenomenon when anodized, its colors reminding of beautiful dragonfly wings or of the elegant shades of peacock feathers. Titanium jewelry always impresses with brilliant metallic colors, being a bio-friendly choice at the same.

In comparison to stainless steel, titanium is stronger and offers a longer service life. For example, titanium rings are often preferred to those made from stainless steel, even though they might cost a little bit more. Once again, it is important to mention that titanium is skin friendly, as it is not mixed with allergenic metals. People who have sensitive skin, being prone to allergies, can wear titanium rings and other types of jewelry without worrying about such matters.

Titanium & clothing

You might not expect titanium to be used in the fashion industry but the truth is that this metal is more versatile than expected. Various fabrics and textiles are coated with titanium, including leather (natural and artificial). Titanium can be used as an agent to reduce the brightness of different fibers, such as spandex, acrylic or nylon. In shoes, titanium might be used as a whitening agent.

Clothing manufacturers have begun to apply nanoparticles of titanium dioxide to diverse items. These have been incorporated into a wide range of textiles, in order to protect the clothes from sun damage. Thanks to this protective layer, these clothes also guarantee enhanced protection against skin damage (as they are reflecting the UV light).

In fabrics with static charge, such as synthetic ones – polyester, nylon – the same technique has been employed. The nanoparticles of titanium dioxide can conduct electricity and thus disperse the electric charge. We are entering the era of smart fabrics, with clothes featuring nano-coating. In the future, more and more fabrics will be made from nanofibers. Manufacturers are hoping for nanoparticles and nanofilaments to become an integral part of the fabric weave.

A nickel-titanium alloy has been used for a smart textile prototype. The fabric developed with this alloy is able to change both its shape and elasticity percentage. These are the modern-generation shape memory alloys, which might be used in the future to develop clothes with self-adapting functions. These can include medical and protective equipment, but also sport items.

Nitinol, as the new alloy has been called, can modify its shape within a wide range of temperatures and has amazing elasticity. However, it has a high price, which means it is at the moment reserved only for the development of unique products. The nitinol filaments might be used for protective equipment, protecting the body from high temperatures (surrounding environment).

Titanium & glasses

Titanium glass frames are all the rage in modern times, being appreciated for their light weight and high level of comfort. In developing these innovative frames, manufacturers might use exclusively titanium or rely on titanium alloys (with iron, aluminum or other metals).

Why should you consider titanium glasses? Because these will last for a long period of time, truly deserving the investment. Titanium frames are recommended to those who suffer from skin allergies, as they are non-allergenic. Moreover, as titanium does not corrode easily, they will definitely remain rust free. They are flexible, retaining their shape upon being bent and require only low maintenance.

Other uses of titanium

Appreciated for its durability and light weight, titanium is used for the making of elegant watch cases. In recent times, both decorative objects and sculptures are made from titanium. Designers have even considered the development of furniture that includes titanium among other elements.

Even coins have been made from titanium. In 1999, for its millennium celebration, Gibraltar has released a coin made exclusively from this metal. In Australia, a medal developed from titanium is awarded to excellent rugby players. These are, however, minor uses of titanium.

One of the most commonly-used titanium alloys is Ti-6A1-4V, an alloy of high strength and whose forming behavior has been studied at room temperature. In order to determine its mechanical properties, as well as the minimum bending radius, scientists have resorted to both tensile tests and swing folding trials. Moreover, they have analyzed the springback behavior through V-die bending tests.

The tests revealed that this particular titanium alloy has a reduced formability, with a high tendency to springback. The material hardening is low as well, which means that stamping or deep drawing are not possible at room temperature. Scientists have also determined that Ti-6A1-4V can be roll formed at room temperature, resulting in simple longitudinal sections.

The formability of the titanium alloy can be improved through roll forming. More importantly, the tendency to springback decreases, especially in comparison through the one observed in the V-die bending tests.
Roll forming reduces the risk of structural defects, representing a potential solution for titanium sheet forming at room temperature. The resulting sections could be useful for applications in different industries, including the aerospace and automotive ones.

Prior inspection is necessary before the actual forming

The titanium sheet has to be inspected before the forming process, regardless of which option the manufacturer might choose. The inspection can identify structural defects but also check how uniform and thick the sheet is (certain standards have to be met). The manufacturer might also analyze how flat it is, paying attention to additional elements, such as strength and hardness. Last, but not least, the bending behavior will be analyzed.

A careful analysis of the titanium sheet will reveal whether the critical regions have been affected by scratches or other marks, such as from grinding (the titanium sheet is quite sensitive, so it must be handled with extra care). If there are scratches presented, these should be removed through grinding.

The titanium sheet has to be properly cleaned before forming. The removal of oxide facilitates the forming process but this is not the only aspect to take into consideration. It is important to eliminate any traces of grease, oil or dirt; in fact, any chemical or residue present on the surface can have a negative influence on the forming process, especially the one performed at high temperatures (hot forming).

In order to ensure the best results for the forming process, the titanium sheet is handled with clean gloves made from cotton. These are worn before and after the forming process, ensuring that no residue will reach the sheet.
Special attention must be paid to sheet grinding, which is performed to finalize the thickness of the sheet but can leave marks. Also, the shearing of the titanium sheet has to be performed with extra care, as there is a risk of cracks occurring.

Cold forming

Cold forming is a process employed not only for commercially-pure titanium but also for the majority of titanium alloys (to a limited extent). Among the titanium alloys which can be formed through this process, there are: Ti-15V-3Sn-3Cr-3A1, Ti-3A1-8V-6Cr-4Zr-4Mo and Ti-8A1-1Mo-1V.

These titanium sheets can be cold formed using the standard process but one has to make sure that the bend is of a larger radius than in hot forming. Also, the stretch flange must be shallower. In the situation that cold forming is used for other alloys, this will lead to excessive springback. Moreover, stress relieving is required, as well as additional power.

The stretch forming of titanium and its alloys can occur at low temperatures (without being heated). However, it must be taken into consideration that the formability of titanium sheets is best at lower forming speeds. In order to reduce stress corrosion and keep the risk of cracks down at a minimum, manufacturers might resort to both stress relieving and hot sizing.

Hot forming

Upon heating the titanium sheet, there are a number of significant changes that take place. The formability increases and the tendency to springback is reduced, allowing for enhanced modifications.

Hot dies are however used for more severe forming. What happens is that the flat titanium sheet is placed in the die and heated to the desired temperature. Slow pressure is applied and the titanium sheet is removed after a period of time. The titanium alloy Ti-6A1-4V is hot formed at temperatures of approximately 730ºC.

It is worth mentioning that the best results, in terms of uniformity and ductility, are obtained when the temperatures go above 540ºC. At higher temperatures, titanium alloys demonstrate a property known as superplasticity; however, they also present a higher risk for more severe contaminations.

If temperatures over 870ºC are used, the forming must be performed in a vacuum or in a protective atmosphere (for example, argon might be used). In general, the superplastic forming can take place at temperatures between 870º and 925ºC, but the temperature has to be monitored at all times. Hot sizing is used to correct shape and size inaccuracies.

As opposed to the previous method, hot forming has a unique advantage to offer. It improves the uniformity of the titanium sheet and the yield strength, as long as both the forming and sizing temperature is over 540ºC.

Superplastic forming

Superplastic forming is a process used for the fabrication of sheet metal components, which are further employed by the aerospace industry. These structures have a light weight and a high level of efficiency to offer.

For this process, there is a computer system used to keep the gas pressure under control. The most commonly-used titanium alloy for superplastic forming is Ti-6A1-4V. As for the limitations of the process, it is worth mentioning that the required tools have to be heat resistant. Longer preheating times are required, as well as a protective atmosphere (argon).

There are different forming processes that can be employed, including blow forming, thermoforming, vacuum forming and deep drawing. The superplastic forming process can be enhanced with diffusion bonding. Contour roll forming is also preferred for the titanium sheet, with special attention being paid to the bend radius (allowable limit). Roll forming remains one of the most cost-advantageous methods for forming the titanium alloy sheets, which will be further used in the aircraft industry.

The next step involves the elimination of impurities, the process being achieved through vacuum distillation. Once the metal chlorides are removed, titanium is purified and the sponge is finally obtained. This will be pressed into blocks and then melted.

Titanium ingots are used for the making of different products, including titanium tubes. Keep on reading and discover more useful information on the process.

Fabrication of titanium products – welded tube

In today’s modern world, more and more companies have shown an interest in the fabrication of titanium products. They possess the necessary technology and equipment to develop titanium tubes, which will be further used by various industries.

The development process has become routine, however, there are certain unique aspects worth taking into consideration. Titanium tubes have to be developed in a perfectly clean environment. In general, there is a separate area reserved for the fabrication of titanium products. It is important that this area does not contain any contaminants, such as dust and grease. Moisture and air drafts have to be absent as well.

Welded titanium tubes have found their use in numerous industries, including the chemical industry. Power plants, especially those that operate in seawater, rely on titanium piping. These tubes are also used for heat exchangers in condensers, being appreciated for their high resistance to corrosion.

Manufacturers might apply additional tension to the titanium tube wall, upon noticing insufficient solidification at the seam of the weld pool. Moreover, in order to ensure that the titanium product remains stable, they might rely on automatic diameter measurement systems. In the future, automatic monitoring systems for seam welding conditions might be introduced as well.

How are titanium tubes formed?

The forming of titanium is achieved at room temperature, the process being similar to the one of steel. Manufacturers rely on the same techniques and equipment, taking into account the unique properties of titanium. This facilitates the tube forming process.

The ductility of titanium, at room temperature, is lower than the one of other structural metals. This automatically translates into a reduced stretch formability and a wider bend radius. Given such characteristics, hot forming is sometimes used, especially if more severe bending is required (or in case of stretch forming).

Titanium’s modulus of elasticity is half the one of steel, which means that the forming process can lead to significant springback (manufacturers will compensate for this characteristic). Also, given the galling tendency of titanium – greater than the one of steel – lubrication is an important part of the tube forming process.

Preparation for forming

In the majority of cases, titanium does not necessitate additional measures to be taken before forming operations. The ingots can be used as they are received but this might not always be valid.

Upon noticing any marks on its surface, such as gouges, these will be removed through different processed (sanding, pickling, etc.). Also, if there are any sharp edges, these should be smoothed out before the actual tube forming process. Otherwise, there is the risk of cracked edges, which will affect the quality of the final product.

Types of forming

Titanium tubes can be formed through two methods: cold and hot forming.

Cold forming

Titanium tubes are formed at a low speed and at room temperature, taking into account the metal’s elongation. For this reason, a tensile test will be performed. The manufacturer will eliminate the springback by using hot sizing on already formed titanium tubes.

Hot forming

It is a known fact that the ductility of titanium – involving bendability and stretch formability – increases with temperature. For this reason, titanium tubes are often realized at high temperatures. It goes without saying that the forming operation of titanium tubes becomes easier with more elevated temperatures. With this method, the springback is practically eliminated on forming grade 5 titanium.

Bending of titanium tubes

Titanium tubes are bent with the use of conventional equipment. The Mandrel tube bending machine is preferred for tight radius bends. In order to minimize titanium’s gail tendency, both the tube bending equipment and the wiper dies must be properly lubricated. For the best results, the bending process should take place at a slow speed.

How is the titanium seamless tube manufactured?

The seamless tube can be developed from commercially-pure titanium or from one of the existent titanium alloys. The titanium ingot is initially processed at a temperature varying between 850 ºC – 1250 ºC, being lastly reduced to 600 ºC – 1100 ºC.

As a result of the processing, a solid billet will be obtained. This will be then turned into a hollow piece, through a piercing process, at a temperature varying between -100 ºC and 1250 ºC.

The size regulation occurs through elongation, followed by a reducing step. This takes a place at a temperature varying between 600 ºC and 1100 ºC, resulting in the reduction of the outside diameter. Last, a sizing step will be taken, at a temperature varying between 550 ºC and 1150 ºC, which will further reduce the outside diameter.

Final word

Titanium tubes are manufactured using the same methods and equipment as for other structural metals. With unique characteristics, these are recommended in environments with high corrosion (where steel would not do the job). The aerospace industry uses titanium tubes on a wide basis, recognizing the benefits offered.

Manufacturers can deliver titanium tubes in various sizes, diameters and wall thicknesses. There are different titanium grades available for the tubes, each having different properties to offer and being suitable for various applications. Each titanium grade respects different technical requirements, being suitable for one type of application or another.

Why should you consider a titanium bike?

A titanium bike will definitely last longer than other types, not to mention it will offer an incredible ride quality. It will basically remind of the steel frame but you will definitely notice a difference with regard to its spring and comfort. Even racing bikes are today made from this metal, with different titanium tubing diameters and profiles.

The majority of titanium frames are made from 3A1/2.5 V tubing, where titanium is alloyed with 3% aluminum and 2.5% vanadium. You might also see another titanium alloy being used, meaning 6A1/4V but this is more expensive and difficult to form. Titanium also offers a unique color, without requiring additional painting (timeless appearance).

What are the general features of a titanium bike?

A bike made from titanium will provide you with the ultimate cycling experience. It will have an elegant frame, with the natural beauty of titanium being more than obvious. Titanium bike frames are only brushed and polished, with no paint or coating.

There are certain features that make titanium bikes unique. For example, there is a later stiffness that contributes to an excellent power transfer. Also, thanks to the vertical compliance, the feedback from the road surface can be easily transferred to the bike. Moreover, such a frame has a unique strength-to-weight ratio, which ensures the necessary rigidity for tough terrains.

Titanium bikes have excellent fatigue life and impact resistance. Apart from that, these frames have an unparalleled corrosion resistance, being able to withstand rust and decay in the most effective manner. They offer permanent deflection and a fabled spring, for a more comfortable cycling experience.

As it was already mentioned above, the frames are made from 3A1/2.5 V titanium alloy. The same kind is used in aerospace applications, being appreciated for the ability to offer a perfect balance between strength and plasticity. You will see titanium tubing used for modern-generation bicycles, guaranteeing a reduced weight and more effective riding possibilities.

The state-of-the-art bicycles of today have two types of tubing. First, you have the seamless titanium tube, which is cold-worked and drawn. Second, there is the seamless hydroformed butted tubing. While both types of tubing are strong and lightweight, being perfect for bike frames, it is true that the latter is more recommended (lighter in weight and capable of lasting for a longer period of time).

What are the latest developments for titanium bikes?

A stylish, titanium bike can weigh no more than one kilo. It is superlight, while guaranteeing high-performance geometry. The top tubes are innovative, being created from 3A1/2.5 V or 6A1/4 V titanium alloys; the titanium square tubing indeed reduces the overall weight of the bike and increases its stiffness (enhanced stability on an otherwise rough or difficult terrain).

The highest-quality titanium bikes available on the market at the moment have cycling-specific tube sets. In some bikes, the titanium frame contributes to the overall performance, regardless of the terrain on which it is used. The tubes have thin walls, which equals a lighter weight and yet a bike that is both agile and responsive, sometimes with dirt capabilities.

It is important to understand that all titanium parts have been fabricated with the idea of offering the best possible cycling experience. These parts are fabricated with the strictest precision in mind, under cold temperatures and worked to suit the needs of the modern-day cyclist.

For example, if you are interested in a gravel racing bike, you can opt for one that has titanium parts (frame in particular can be made from lightweight titanium alloys). By using titanium tubes, manufacturers offer cyclists the vertical compliance they need; thus, these tubes act as subtle springs and improve the overall quality of the ride.

Nowadays, on the specialized market, one can find titanium bikes that are light and aerodynamic. These bikes have been adapted to the terrain and its demands; titanium is used not only for the development of urban bikes but also for the gravel and mountain bike. It offers the perfect blend of raw durability and precise handling, as well as traction. On a titanium bike, you will cycle without being worried about the ride quality or terrain.

Yes or no to titanium bikes?

The answer should definitely be yes. A bike that has a titanium frameset will allow you to cycle on a difficult terrain, without the ride quality being affected by, let’s say, a bumpy surface. Thus, the whole ride will be comfortable and you will certainly want to repeat the cycling experience.

Recently, manufacturers have begun using a carbon fork in combination with the titanium frame, so as to improve the road comfort even further. The titanium bike is light and tough, offers a comfortable ride and, when designed in an effective manner, it offers the best possible propulsion on various terrains. As an experienced cyclist, you will definitely notice the incredible response it offers.

In the future, manufacturers will continue to refine the production of titanium bikes, especially with regard to the tube sets. Cyclists will be able to purchase titanium bikes, which have been made to adapt not only to the type of terrain on which they are used but also to the rider himself/herself.

Products like the titanium alloy bar or the titanium alloy sheet have become increasingly used in developing countries. China is, at the moment, one of the top countries using titanium for various applications, being closely followed by India, Brazil and Mexico. Saudi Arabia is another developing country with an industrial activity that is based more and more on the use of titanium.

There are three main factors that have contributed to the increased global demand for titanium and its alloys, meaning high levels of urbanization, development of industrial activities and population growth. In China, for example, as the number of passengers increased, this led to a higher demand for aircrafts. The same change was noticed in India, with titanium soon being used for the making of aircraft parts.

China, a leading market for titanium (Asia-Pacific area)

The titanium tube, titanium sheet and titanium bar represent just three of the many products used by Chinese industries with success. China is a leading market for titanium, its applications being found in the automotive, aircraft, power, medical, desalination and chemical industries. India follows as the second-largest producer and consumer of titanium alloys in the Asia-Pacific region.

It is true that titanium is one of the most significant raw materials used in the aerospace industry, with alloys occupying a large percentage of the total. Today, titanium is used for the making of both aircraft engines and blades; even the shaft, landing gear, wing beams and fasteners can be made using titanium and its alloys. This is often related to the fact that titanium can operate at extreme temperatures, without its structure of functionality being affected.

Desire for fuel efficiency led to titanium being used for lightweight vehicles

In the past few years, the automotive industry has been under pressure to improve fuel efficiency and reduce harmful emissions at the same time. Manufacturers have begun to turn to alternative materials, such as titanium, in order to be able to reduce the weight of a vehicle considerably. Thus, titanium began to be used for the development of modern-generation, lightweight vehicles.

How did manufacturers manage to reduce the actual weight of a vehicle? They started to incorporate polycarbonates into the vehicle structure, using them to replace parts otherwise made from steel. However, it was soon discovered that these materials had a low scratch resistance and turned to titanium dioxide as coating.

The use of titanium dioxide on polycarbonate structure has contributed to the reduction of vehicle weights, improving fuel efficiency as a natural consequence. Apart from that, the titanium dioxide coating offered a more appealing color, not to mention added strength and opacity.

Other industries have driven the demand for titanium up. In the construction industry, titanium dioxide might be used as coating for green cement (in the form of nanoparticles). The paint industry relies on titanium for the development of highly-resistant coatings. Overall, the global titanium dioxide market was valued at $13.3 billion in 2015.

End-user industries will fuel the demand for titanium in the future

As previously mentioned, titanium is a commonly-chosen material for the development of coatings. Titanium pigments are added to various paints and coatings, with the demand for such substances continuing to increase. This is particularly important to mention, as more and more manufacturers are interested in developing products that are both environmentally-friendly and highly resistance to corrosion.

Titanium dioxide nanoparticles are more and more often used by green industries. For example, these have been developed to be used in photovoltaic systems; titanium is an excellent material for dry-sensitized solar cells, having the ability to improve their performance. The paper & pulp industry uses titanium pigments as well, not to mention titanium is a common ingredient of various cosmetics.

The titanium sponge, a product of interest for many industries

The titanium sponge is one of the most interesting products, being used in various industrial applications. As technology evolved, the titanium melt capacity has increased and, thus, the number of steps required to obtain the sponge reduced. This led to titanium becoming a premium grade material, with countries such as China, USA, Russia and Japan investing in titanium production.

Why is the titanium sponge so appreciated? It represents one of the purest forms of this metal, being used as a base for other products, including titanium tubing, titanium piping and titanium pipe fittings. The titanium sponge has a high corrosion resistance, it can withstand both shocks and extreme temperatures. Moreover, has a low weight and a reduced maintenance cost; it is both biocompatible and recyclable.

China is the leading producer of titanium sponge, followed by Japan, Kazakhstan, Russia and Ukraine. As for the export destinations, these include European countries, as well as the USA and South Korea. The titanium sponge is primarily used in the aerospace industry but it has found its use in other applications as well, such as the military.

Final word

The global demand for titanium and its alloys will keep on increasing, the growth being strongly driven by emerging markets. In the future, we will see titanium being used for innovative applications, changing the way both humans and industries function. Companies from various fields will rely on titanium for industrial applications, appreciating this metal for its unique properties.

Titanium dioxide will no doubt contribute to this increased demand, being used for paints and coatings, as well as making a genuine difference in the automotive industry. As for the titanium sponge, the research will be focused on simplifying the production process even further. With the manufacturing process simplified, more and more countries will become interested in the titanium sponge and its subsequent applications.

Titanium has a number of specific properties, being used either in its commercially pure form or as alloys. As you will see, the primary attribute which makes titanium an attractive material is the high strength-to-weight ratio. The metal also has excellent corrosion resistance, it is compatible with the human body and it can be used for combat vehicles, thanks to its excellent ballistic resistance.

High strength-to-weight ratio

Both commercially-pure titanium and its alloys, in different forms – titanium alloy bar, titanium alloy sheet – have high strength and low weight. You might be interested to know that titanium is as strong as steel but it is forty percent lighter in weight. This is one of the main reasons for which titanium is preferred as a structural metal for aerospace applications.

Titanium is a strong metal, with a low density. Given this property, as well as the resistance to high temperature, it should come as no surprise that the metal is used in the aerospace industry. Both airplane parts and fasteners can be made from titanium. The same goes for gas turbine engines and other parts, such as heat shields, compressors blades, engine cowlings and casings.

This ratio can lead to weight savings, making titanium an excellent choice for aircraft parts, such as the landing gear (Boeing, Airbus). Moreover, it has a high resistance to corrosion, which can mean a reduction in the maintenance costs for the respective landing gear structure. The same properties have made titanium a preferred choice for automotive applications – both regular vehicles and racing cars can use connecting rods made from titanium.

Excellent resistance to corrosion

Titanium has an excellent resistance to corrosion, including when exposed to seawater and chemical substances. What happens is that a thin layer for titanium dioxide forms on its surface, making it difficult for other materials to penetrate the respective structure. Its resistance to corrosion is another reason that led to titanium being used for aircrafts.

At ambient temperature, the metal reacts with both water and air, forming the above-mentioned coating. This protects the structure in question from further oxidation. Interestingly, the protective layer will continue to grow with the passing of time.

Given its resistance to corrosion , titanium can resist attacks from organic acids, as well as from dilute sulfuric and hydrochloric acids. However, it does react with gases, including nitrogen and oxygen. For this reason, titanium filaments are used in vacuum systems – the metal is an integral part of pumps.

The metal finishing industry relies on the use of titanium for the making of linings, heat exchanger coils and jigs. Titanium is a popular material in the chemical processing industry as well, as it can resist both chlorine and acid. It can be used for the development of the heat exchanger titanium coil, pumps and titanium valves.

In the oil refining industry, titanium is used for the making of condenser tubes and appreciated for its exceptional corrosion resistance. As it resists to corrosion even when in seawater, titanium has been employed for various equipment items used in desalination plants.

Given this resistance, titanium has been used as coating, guaranteeing absolute best protection to structures exposed to seawater (submarines, ship hulls). Titanium oxide has excellent covering powering, being used as a paint pigment or enamel. Both the plastics and the paper industry have made use of titanium oxide, which a bright white pigment.

Low modulus of elasticity

Even though titanium does not have a high flexibility rate, it does return to its original shape after being bent. Titanium is nevertheless ductile, particularly when being used in oxygen-free environments.

The low modulus has led to titanium being used as a replacement for steel springs. With a modulus half as the one of steel, this meant that the number of necessary coils could be reduced to half. This automatically translated into weight savings, as well as reduced maintenance costs (corrosion resistance and high strength).

Biocompatibility

As titanium has a high biocompatibility percentage, being non-toxic and non-allergenic, it has found an increasing use in the medical field. Titanium is today used for the development of medical implants.

These include joint replacements, especially for the hips and elbows, as well as pacemakers, tooth implants and defibrillators. Doctors were even able to use titanium for the development of an artificial heart. Titanium crutches are considered to be more effective and resistant on a long-term basis.

High melting point

Titanium has a relatively high melting point, which makes it an excellent refractory metal. The metal is often used in solar observatories, reflecting the infrared radiation and improving visibility (poor visibility is caused by heat).

Other properties of titanium

Whether we are talking about the titanium tube, titanium sheet or titanium bar, it is important to remember that all of these items are non-magnetic. Strong and less dense as steel, titanium is used for the development of spacecraft parts and missiles.

In the past few years, titanium has also been used for the making of sporting goods, such as golf clubs, bicycles and ice skates. Today, even laptops have certain parts made from titanium. As for titanium oxide, this is used as an ingredient in sunscreens; given its refractory and coating properties, it can prevent UV light from reaching the skin.

Titanium has an excellent ballistic resistance, being used for adequate protection in military applications. It offers weight savings, especially in comparison to other materials such as steel or aluminum.

The metal is used in military ground combat vehicles; as these vehicles are lighter, they can be more efficiently maneuvered and the transportability quality increases. Moreover, titanium has excellent corrosion resistance and it is highly compatible with composites, being ideal for infantry fighting vehicles and battle tanks.

A final word

The main properties of titanium include the high strength-to-weight ratio, excellent corrosion resistance and low elasticity modulus. Titanium is compatible with the human body, it has a high melting point and it has efficient refractory properties. All of these characteristics make it an ideal choice for today’s high demands of various industries, including the aerospace, military and chemical processing ones.