Working Titanium

Keep titanium particles away from sources of ignition. Small particles of titanium burn very easily. In sufficient concentration, these small particles can cause an explosion. If water touches molten titanium, a steam explosion could occur. Extinguish titanium fires with dry talc, calcium carbonate, sand, or graphite. Apply the powder on the burning metal to a depth of 1⁄2-inch or more. Do not use foam, water, carbon tetrachloride, or carbon dioxide.

Description of Titanium


Titanium in its mineral state, is the fourth most abundant structural metal in the earth’s crust. It is light weight, nonmagnetic, strong, corrosion resistant, and ductile. Titanium lies between the aluminum alloys and stainless steel in modulus, density, and strength at intermediate temperatures. Titanium is 30 percent stronger than steel, but is nearly 50 percent lighter. It is 60 percent heavier than aluminum, but twice as strong.

Titanium and its alloys are used chiefly for parts that require good corrosion resistance, moderate strength up to 600 °F (315 °C), and light weight. Commercially pure titanium sheet may be formed by hydropress, stretch press, brake roll forming, drop hammer, or other similar operations. It is more difficult to form than annealed stainless steel. Titanium can also be worked by grinding, drilling, sawing, and the types of working used on other metals. Titanium must be isolated from magnesium, aluminum, or alloy steel because galvanic corrosion or oxidation of the other metals occurs upon contact.

Monel® rivets or standard close-tolerance steel fasteners should be used when installing titanium parts. The alloy sheet can be formed, to a limited extent, at room temperature.

The forming of titanium alloys is divided into three classes:
  • Cold forming with no stress relief
  • Cold forming with stress relief
  • Elevated temperature forming (built-in stress relief)
Over 5 percent of all titanium in the United States is produced in the form of the alloy Ti 6Al-4V, which is known as the workhorse of the titanium industry. Used in aircraft turbine engine components and aircraft structural components, Ti 6Al-4V is approximately 3 times stronger than pure titanium. The most widely used titanium alloy, it is hard to form.

The following are procedures for cold forming titanium 6Al-4V annealed with stress relief (room temperature forming):
  1. It is important to use a minimum radius chart when forming titanium because an excessively small radius introduces excess stress to the bend area.
  2. Stress relieves the part as follows: heat the part to a temperature above 1,250 °F (677 °C), but below 1,450 °F (788 °C). Keep the part at this temperature for more than 30 minutes but less than 10 hours.
  3. A powerful press brake is required to form titanium parts. Regular hand-operated box and pan brakes cannot form titanium sheet material.
  4. A power slip roller is often used if the repair patch needs to be curved to fit the contour of the aircraft.
Titanium can be difficult to drill, but standard high-speed drill bits may be used if the bits are sharp, if sufficient force is applied, and if a low-speed drill motor is used. If the drill bit is dull, or if it is allowed to ride in a partially drilled hole, an overheated condition is created, making further drilling extremely difficult. Therefore, keep holes as shallow as possible; use short, sharp drill bits of approved design; and flood the area with large amounts of cutting fluid to facilitate drilling or reaming.

When working titanium, it is recommended that you use carbide or 8 percent cobalt drill bits, reamers, and countersinks. Ensure the drill or reamer is rotating to prevent scoring the side of the hole when removing either of them from a hole. Use a hand drill only when positive-power-feed drills are not available.

The following guidelines are used for drilling titanium:
  • The largest diameter hole that can be drilled in a single step is 0.1563-inch because a large force is required. Larger diameter drill bits do not cut satisfactorily when much force is used. Drill bits that do not cut satisfactorily cause damage to the hole.
  • Holes with a diameter of 0.1875-inch and larger can be hand drilled if the operator:

     - Starts with a hole with a diameter of 0.1563-inch
     - Increases the diameter of the hole in 0.0313-inch or 0.0625-inch increments.

  • Cobalt vanadium drill bits last much longer than HSS bits.
  • The recommended drill motor rpm settings for hand drilling titanium are listed in Figure.
Hole size and drill speed for drilling titanium

  • The life of a drill bit is shorter when drilling titanium than when drilling steel. Do not use a blunt drill bit or let a drill bit rub the surface of the metal and not cut it. If one of these conditions occurs, the titanium surface becomes work hardened, and it is very difficult to start the drill again.
  • When hand drilling two or more titanium parts at the same time, clamp them together tightly. To clamp them together, use temporary bolts, Cleco clamps, or tooling clamps. Put the clamps around the area to drill and as near the area as possible.
  • When hand drilling thin or flexible parts, put a support (such as a block of wood) behind the part.
  • Titanium has a low thermal conductivity. When it becomes hot, other metals become easily attached to it. Particles of titanium often become welded to the sharp edges of the drill bit if the drill speed is too high. When drilling large plates or extrusions, use a water soluble coolant or sulphurized oil.
NOTE: The intimate metal-to-metal contact in the metal working process creates heat and friction that must be reduced or the tools and the sheet metal used in the process are quickly damaged and/or destroyed. Coolants, also called cutting fluids, are used to reduce the friction at the interface of the tool and sheet metal by transferring heat away from the tool and sheet metal. Thus, the use of cutting fluids increases productivity, extends tool life, and results in a higher quality of workmanship.