Wexmar provides Ti-6Al-4V titanium CNC machining for aerospace hardware, defense build-to-print parts, medical hardware and demanding industrial components. Ti-6Al-4V, known as Grade 5, is the workhorse titanium alloy, offering high strength-to-weight, corrosion resistance and good fatigue life. It is also slow and punishing to cut, which is why process discipline matters more than raw spindle horsepower. We machine it from bar and plate on lathes, horizontal mills and Swiss machines in Canastota, New York.
Titanium machinability rating
Ti-6Al-4V rates approximately 22 against AISI 1212 steel at 100. The alloy has low thermal conductivity, so heat stays at the tool edge instead of leaving with the chip. It is chemically reactive with tool materials at temperature, and its low modulus lets thin features spring away from the tool. Typical surface speeds are a fraction of what alloy steel allows, and tool life, not spindle speed, sets the cycle.
In practice this means a Grade 5 part that takes a few minutes in 6061 aluminum can take several times longer, with more tool changes and closer monitoring of edge condition. Our horizontal machining centers help here: pallet changers keep spindles cutting while the next part is loaded, and the rigid horizontal spindle and tombstone fixturing hold the part firmly against the cutting forces titanium produces. On lathes, we favor short tool overhang and full-length support for slender shafts.
Tolerances and finish on Grade 5 parts
For Grade 5 titanium we typically hold plus or minus 0.0005 in. on turned diameters and plus or minus 0.001 in. on milled features, with true position and profile verified on our CMMs. Typical surface finish is 63 Ra as machined, with 32 Ra common on turned and bored surfaces. Thin walls and long slender parts limit what is practical, so we review those features at quote. These numbers are typical, not guaranteed.
Heat, tooling and chip control in Ti-6Al-4V
- Keep the tool cutting. Dwelling or rubbing hardens and glazes the surface, and the next pass then wears the edge faster.
- Sharp coated carbide with positive geometry, moderate speed and a steady, relatively heavy chip load outperforms light, fast passes.
- High-pressure flood coolant is essential for heat removal and chip evacuation, especially in drilling and grooving.
- Rigid setups matter. Low stiffness causes chatter and taper on thin walls, so we support the part and step down in stages.
- Chip safety: fine titanium chips and grinding dust are a fire hazard, so chips are kept wet and segregated from other metals.
- Stress: heavily machined parts can move after roughing, and stress relief between roughing and finishing is arranged when geometry calls for it.
Heat treat and finish options
Ti-6Al-4V is supplied annealed or solution treated and aged (STA). Stress relief, annealing and aging are performed through qualified outside processors. Common finishes include Type II titanium anodize for color coding or anti-galling, passivation or pickling to clean the surface, and bead or media blasting, also through qualified outside processors. We sequence these steps so critical dimensions are finished after any operation that could move them.
Common Grade 5 titanium parts and processes
- Fasteners, pins and spacers up to 32 mm diameter: Swiss machining on Maier MLK-32 machines
- Fittings, bushings, housings and shafts: CNC turning with live tooling and Y-axis
- Brackets, clevises and mounting blocks: 4-axis horizontal milling with pallet changers
- Medical hardware components built to customer drawings
- Pump and valve components for corrosive or seawater service
Cost index versus 6061 aluminum
| Material | Approx. machinability (1212 = 100) | Cost index vs 6061 | Notes |
|---|---|---|---|
| Ti-6Al-4V (Grade 5) | ~22 | 5.0 | High strength, heat sensitive |
| CP titanium Grade 2 | ~35 | 4.0 | Softer, gummier |
| 17-4 PH stainless (Cond A) | ~40 | 2.8 | Heavier, lower cost |
| 316 stainless | ~36 | 2.5 | Corrosion resistant, heavier |
| Inconel 718 (annealed) | ~12 | 8.0 | For higher temperatures |
| 6061-T6 aluminum | ~180 | 1.0 | Cost index baseline |
Values are typical and illustrative for a comparable part; actual quotes depend on geometry, quantity, tolerances and mill pricing.
Industries and applications
Grade 5 titanium parts from our shop support aerospace hardware, defense and government build-to-print programs, medical hardware, and industrial equipment exposed to seawater or chemicals. For DoD work, DFARS 252.225-7009 specialty-metals-compliant sourcing is available, with material certs and heat-lot traceability through our quality system. Where strength matters less than formability and corrosion resistance, CP Grade 2 titanium is often the lower-cost choice.
Getting a quote
For titanium work, upload a drawing for an instant estimate or call (315) 400-2654. A human estimator confirms every quote and checks the material specification, condition and any DFARS requirement before pricing is final.