In the world of advanced materials, the choice between Grade 2 vs Grade 5 titanium is a pivotal decision for procurement managers and supply chain professionals.
This decision goes beyond technical specs—it directly shapes project timelines, manufacturing costs, and long-term reliability.
This guide outlines a practical framework to support sourcing decisions that are strategic, cost-conscious, and aligned with operational risk.
Executive Summary for Procurement Professionals:
Grade 2 Titanium (UNS R50400): A benchmark in cost-effective reliability. With superior corrosion resistance and simplified manufacturability, it suits industrial and marine applications prioritizing budget control and process predictability.
Grade 5 Titanium (UNS R56400 / Ti-6Al-4V): Engineered for high-performance needs. When strength-to-weight ratio is critical—like in aerospace or performance machinery—Grade 5 becomes indispensable.
The Bottom Line: Selecting the wrong grade risks budget overruns or product failure. This guide offers a system-level view for evaluating total cost of ownership and minimizing sourcing risks.
Case Study: A Single Part Failure and Its Supply Chain Impact
To demonstrate the significance of correct material selection, consider a real-world sourcing scenario. A manufacturer of autonomous underwater vehicles (AUVs) specified Grade 5 titanium (Ti-6Al-4V) for a manipulator arm bracket, emphasizing its high strength.
Though the material met technical requirements, fabrication complexity became a key obstacle.
The intricate geometry complicated inert gas shielding during TIG welding, and inconsistent post-weld heat treatment (PWHT) left high residual stresses.
In a chloride-rich deep-sea environment, this led to a failure from Stress Corrosion Cracking (SCC).
Key Takeaways for Procurement:
Specification vs. Reality: High-performing materials on paper can become liabilities if they introduce excessive manufacturing risk.
Process Drives Reliability: Grade 5’s processing complexity nullified its strength advantage, resulting in costly operational failure.
Strategic Fit Matters: Grade 2, with its SCC resistance and simpler processing, could have prevented the failure. Material choice must consider the full manufacturing context.
Meet Your Tools: The Core Identity Cards of Two Titans
Understanding the character of each grade helps align material selection with application realities and cost control.
Player 1: Grade 2 (The Resilient Generalist)
Identity: Commercially Pure (CP) Titanium, The Environmental Master.
Grade 2 is the most commonly used CP titanium. Its strength lies in its purity, offering moderate strength, excellent ductility, and exceptional corrosion resistance.
It’s the default choice for long-term exposure to harsh environments.
Core Identity Card:
Strength Rating: ★★☆☆☆ (Moderate)
Corrosion Resistance: ★★★★★ (Exceptional)
Formability: ★★★★★ (Excellent)
Weldability: ★★★★★ (Simple)
Cost Index: ★★☆☆☆ (Lower)
Procurement Perspective: For high-reliability use in corrosive environments with predictable manufacturing costs, Grade 2 is the standard.
Grade 2’s corrosion resistance stems from a self-healing TiO₂ film, which shields it from seawater and chemical exposure. Its superior formability enables cost-effective fabrication of components like tubing and pressure vessels. Straightforward weldability with no PWHT simplifies production workflows.
Player 2: Grade 5 / Ti-6Al-4V (The High-Performance Specialist)
Identity: Alpha-Beta Alloy, The Strength Virtuoso.
Grade 5, or Ti-6Al-4V, is the most widely used titanium alloy. Aluminum and vanadium additions give it a remarkable strength-to-weight ratio and allow for heat treatment.
Core Identity Card:
Strength Rating: ★★★★★ (Very High)
Corrosion Resistance: ★★★★☆ (Excellent)
Formability: ★★☆☆☆ (Fair / Requires Heat)
Weldability: ★★☆☆☆ (Complex)
Cost Index: ★★★★☆ (Higher)
Procurement Perspective: When the design demands peak strength and weight efficiency—and advanced processing is feasible—Grade 5 is the go-to alloy.
Its strength-to-weight ratio is key in sectors like aerospace or motorsports. Grade 5 can be heat treated for enhanced properties. For medical applications, its purer variant, Grade 23 (Ti-6Al-4V ELI), is favored under ASTM F136 for its superior fracture toughness.
Technical Specifications: A Head-to-Head Data Comparison
Procurement teams must justify specs with standards. The following tables summarize the key differences:
Chemical Composition (ASTM B348, weight %)
| Element | Grade 2 | Grade 5 |
|---|---|---|
| Titanium (Ti) | Balance | Balance |
| Aluminum (Al) | — | 5.5–6.75 |
| Vanadium (V) | — | 3.5–4.5 |
| Iron (Fe) | ≤ 0.30 | ≤ 0.40 |
| Oxygen (O) | ≤ 0.25 | ≤ 0.20 |
| Carbon (C) | ≤ 0.08 | ≤ 0.08 |
| Nitrogen (N) | ≤ 0.03 | ≤ 0.05 |
| Hydrogen (H) | ≤ 0.015 | ≤ 0.015 |
Mechanical & Physical Properties (Annealed Condition)
| Property | Grade 2 | Grade 5 (Ti-6Al-4V) |
| Ultimate Tensile Strength | 345 MPa (50,000 psi) | 950 MPa (138,000 psi) |
| Yield Strength | 275 MPa (40,000 psi) | 830 MPa (120,000 psi) |
| Elongation at Break | 20% | 14% |
| Hardness (HRB/HRC) | 82 HRB | 36 HRC |
| Density | 4.51 g/cm³ | 4.43 g/cm³ |
| Modulus of Elasticity | 103 GPa | 113.8 GPa |
| Melting Point | 1665°C | 1660°C |
The Workshop Truth: Uncovering the Hidden Costs from Print to Part
Understanding the downstream impact of each grade is essential to managing timelines and budgets.
Welding Strategy: Simplicity vs. Sensitivity
Grade 2 supports straightforward TIG welding without post-weld heat treatment. This reduces workflow bottlenecks.
Grade 5 demands advanced shielding and mandatory PWHT, increasing complexity, risk, and limiting supplier availability.
The Art of Machining: Tool Life and Cycle Times
Grade 2 machines efficiently, keeping lead times short.
Grade 5’s low thermal conductivity and high strength accelerate tool wear. Specialized tools and slower speeds raise costs—often 2–4× that of Grade 2.
Surface Finishing: Aesthetic and Functional Factors
Both grades accept bead blasting and anodizing. However, anodized colors on Grade 5 are less vibrant due to alloying elements—potentially relevant for consumer products.
Inspection and Total Cost Model
Grade 2 parts usually require standard inspection. Grade 5 components—especially welded—often need ultrasonic testing (UT) and other NDT, increasing cost.
Total Part Cost = Material + (Machining × Rate) + Tooling + Welding + QC + Scrap Risk
This equation shows how Grade 5 parts can cost 3–5× more than similar Grade 2 parts.
The Final Decision: Arming Your Project for Success
The right choice depends on performance requirements and fabrication capability.
Application-Driven Decision Paths
Corrosion-First: Marine, chemical, desalination → Grade 2
Strength-First: Aerospace, motorsport, medical → Grade 5
The Engineer’s Matrix
(Include matrix in visual layout)
X-Axis: Performance Needs (Low → High)
Y-Axis: Cost/Complexity (Low → High)
Sweet Spot: Low needs, low cost → Grade 2
Performance Zone: High needs, high complexity → Grade 5
Over-Engineering Trap: Low needs, high complexity → Avoid Grade 5
High-Risk Gamble: High needs, low complexity → Avoid Grade 2
This matrix supports evidence-based sourcing.
A Final Word: Success Depends on Material AND Partner
Selecting the right titanium grade is only the beginning.
Your manufacturing partner’s expertise ensures the material reaches its potential. At YISHANG, we bring process control, titanium know-how, and technical guidance that transform specs into high-performance parts.
Consult with our engineering team to streamline your supply chain and achieve precision at scale.