Custom titanium fabrication is chosen when low density, strength, temperature capability or corrosion resistance justifies a higher material and process cost. The challenge is that titanium cannot be treated like expensive stainless steel. Grade, oxygen pickup, tool cleanliness, forming radius, weld shielding and traceability all affect the finished part.
This guide is for buyers sourcing titanium sheet, plate and fabricated assemblies for aerospace and corrosive-service equipment.
Process rule - Lock the titanium grade and product form, separate titanium from carbon-steel contamination, use conservative forming data, shield weld metal and the hot heat-affected zone from air, and define inspection and traceability before quoting. Ask the supplier for process evidence on the same grade and thickness range.
Choose the grade by function
| Grade | General character | Typical fabricated use |
|---|---|---|
| Grade 1 | Highest ductility, lower strength | Deep forming, heat exchangers, corrosive process parts |
| Grade 2 | Commercially pure, balanced strength/formability | Tanks, covers, ducts, marine and chemical equipment |
| Grade 5 (Ti-6Al-4V) | High strength, lower cold formability | Aerospace brackets, structural components, machined parts |
| Grade 9 (Ti-3Al-2.5V) | Medium strength and good formability | Tubing, lightweight frames and aerospace structures |
Do not permit an unspecified “titanium equivalent.” Chemistry, mechanical properties, bend response and qualification requirements differ. State the applicable ASTM, AMS or customer specification and product form.
Our titanium material capabilities page covers available fabrication routes.
Aerospace versus corrosion-driven parts
Aerospace parts normally emphasize weight, fatigue, traceability and controlled processes. Corrosive-service parts emphasize media compatibility, weld integrity, cleanliness and leak performance.
The same bracket geometry may need a different quality plan depending on application:
- Aerospace mounting bracket: material lot, grain direction, dimensional report and controlled special processes.
- Chemical equipment tray: media compatibility, drainage, weld shielding and surface cleanliness.
- Marine cover: galvanic isolation, fastener selection and crevice avoidance.
- Heat-exchanger housing: weld integrity, leak testing and thin-sheet distortion control.
Tell the supplier the service condition. Material grade alone does not define acceptance.
Material cost and nesting
Titanium stock costs more than common steel or aluminum, so nesting and scrap strategy matter. Buyers can reduce avoidable cost by:
- Sharing thickness and grade across a part family.
- Avoiding unnecessary cosmetic stock allowance.
- Permitting practical grain orientation where fatigue/forming allows it.
- Combining production quantities for material purchasing.
- Approving remnant use only with preserved traceability.
- Separating prototype economics from production pricing.
Do not sacrifice critical grain direction or traceability for nesting yield. State which features control orientation.
Cutting and edge preparation
Fiber laser, waterjet, machining and sawing can cut titanium when the process is selected around thickness, edge quality and heat effects. The fabrication plan should control:
- Dross and recast condition.
- Heat tint or oxidation at cut edges.
- Burr removal without iron contamination.
- Edge radius at fatigue-sensitive features.
- Cleanliness before forming or welding.
- Stock identity after blanks are separated.
For aerospace fatigue parts, the drawing or governing process may require additional edge finishing or inspection beyond standard laser-cut quality.
Forming titanium sheet
Commercially pure grades are more formable than Ti-6Al-4V, but all titanium forming needs attention to springback and galling.
Check:
- Minimum inside radius for the specific grade, thickness and direction.
- Rolling direction relative to the bend.
- Larger springback compensation than mild steel.
- Clean, smooth tooling.
- Lubricant compatibility and complete removal.
- Hot forming or stress relief when the geometry requires it.
Grade 5 sheet often requires generous radii and process validation. Do not release a tight aluminum-like radius because the CAD model permits it.
Welding and shielding
Hot titanium reacts readily with oxygen, nitrogen and hydrogen. Welding therefore requires shielding not only over the molten pool but also over the hot trailing weld and often the back side.
A controlled titanium weld process may use:
- High-purity inert shielding gas.
- Trailing shields and purge fixtures.
- Clean dedicated brushes and preparation tools.
- Degreased joint surfaces.
- Controlled interpass temperature.
- Weld-color acceptance criteria.
- Qualified procedures and personnel where required.
Dark blue, gray or chalky weld color can indicate excessive atmospheric contamination. Appearance limits should follow the applicable engineering specification, not a generic color preference.
Prevent cross-contamination
Embedded carbon-steel particles and dirty tooling can compromise titanium surfaces and welding. Audit the supplier’s controls:
- Dedicated or thoroughly cleaned tooling.
- Separate stainless/titanium brushes.
- Protected storage and work surfaces.
- Clean gloves for final handling.
- No grinding sparks from carbon steel onto titanium.
- Controlled markers, tapes and cleaners.
For critical work, ask to see the actual preparation and welding area rather than accepting a written statement.
Galvanic corrosion and joint design
Titanium is corrosion resistant but can drive galvanic attack in less noble metals coupled to it in an electrolyte. Review aluminum, carbon steel and fastener interfaces.
Possible controls include:
- Electrical isolation washers or coatings.
- Compatible fastener selection.
- Drainage that avoids persistent wet crevices.
- Sealed interfaces where appropriate.
- Replaceable sacrificial components.
Do not place an insulating coating under a joint that also needs electrical bonding without resolving the conflict explicitly.
Inspection and quality records
Match inspection to part risk:
- Material certificates and heat/lot traceability.
- Positive material identification where required.
- First-article dimensional inspection.
- Weld visual inspection and penetrant testing.
- Leak or pressure testing for fluid equipment.
- Surface contamination or cleanliness controls.
- Special-process certificates.
- Packaging that preserves surface condition and identity.
For traceability structure, see our material test report guide.
Cost drivers
The main quotation drivers are:
- Grade, thickness and certified stock availability.
- Material yield and remnant policy.
- Forming severity and need for hot work.
- Weld length, purge access and shielding fixtures.
- Machined features and tight tolerances.
- Nondestructive testing and documentation.
- Surface condition and protected packaging.
- Prototype versus repeat volume.
An unusually low quote may omit certified material, controlled shielding, inspection or the expected scrap rate. Compare scope before comparing totals.
Titanium fabrication RFQ checklist
- Grade, product form and governing specification.
- Material certification and traceability level.
- Formed 3D model and controlled drawing.
- Grain-direction and bend-radius requirements.
- Weld standard, shielding and inspection criteria.
- Service media, temperature and galvanic interfaces.
- Surface, cleanliness and packaging requirements.
- Prototype, batch and annual quantities.
Related customer project: Titanium Aerospace Bracket: Post-Weld Stability. Related resources: custom titanium fabrication scope · aerospace industry capabilities · send the material specification and drawing.
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