Aluminum 6061-T6 vs. DMLS Ti-6Al-4V ELI Titanium

Compare Aluminum 6061-T6 vs. DMLS Ti-6Al-4V ELI Titanium strength, stiffness, weight and thermal properties.

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DMLS Ti-6Al-4V ELI Titanium3D printed metal (DMLS)

Mechanical
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Yield strength	276MPasourcetypical, 0.2% offset, .500 in dia specimen	1,100MPasourcetypical, as built, average of horizontal + vertical (M400)
Ultimate tensile strength	310MPasourcetypical	1,270MPasourcetypical, as built, average of horizontal + vertical (M400)
Elongation at break	17%sourcetypical, in 4D, 0.500 in dia specimen	8.7%sourcetypical at break, as built (M400)
Young's modulus (stiffness)	68.3GPasourcetypical	110GPasourcesame maker and process, sibling grade: EOS Titanium Ti64 (Grade 5) on EOS M 290, as built, XY and Z, typical
Density	2,700kg/m³sourcenominal	4,400kg/m³sourcetypical part density (ISO 3369), M400
Strength to weight	102kN·m/kg	250kN·m/kg2.45x higher
Stiffness to weight	25.3MN·m/kg1% higher	25MN·m/kg
Poisson's ratio	0.33sourcetypical (handbook physical constant)	0.342sourcewrought TIMETAL 6-4 (TIMET measurement, mean of 10); composition-level, not DMLS-measured
Shear modulus	25.7GPa	41GPa1.6x stiffer in shear
Bulk modulus	67GPa	116GPa
Speed of sound	5,030m/s	5,000m/s
Thermal
Thermal conductivity	167W/m·Ksourcetypical, 20 °C	6.6W/m·Ksourcebase material: wrought Ti-6Al-4V / 6-4 ELI (TIMET datasheet), 20 °C
Thermal expansion	23.6µm/m·Ksourcetypical, mean 20-100 °C	9µm/m·Ksourcemean 25-100 °C, ASTM E228; EOS Ti64 Grade 23 (=ELI) on EOS M 290 40 µm; condition not stated (sheet's mechanical data are heat treated)
100 mm part over a 50 °C swing	118µm growth	45µm growth2.62x less
Specific heat	896J/kg·Ksourcetypical, at 100 °C	580J/kg·Ksourcebase material: wrought Ti-6Al-4V / 6-4 ELI (TIMET datasheet), 20 °C
Heats up and cools (diffusivity)	69mm²/s26.7x faster	2.59mm²/s
Thermal shock resistance	19,159W/m3.97x more resistant	4,825W/m
Melting point	582–652°Csourcesolidus-liquidus	1,630–1,650°Csourcemelting range, wrought TIMETAL 6-4 (composition-level)
Values for	6061-T6/T651, Kaiser Aluminum typical properties; Poisson from MIL-HDBK-5J	EOS Titanium Ti64ELI (powder 9011-0040; ASTM F136/F3001, i.e. Grade 23) on EOS M400 SF, parameter set Ti64ELI_030_FlexM400_100, 30 µm, as built; ISO 6892-1 A14

Every value links to the document that states it. "Not sourced" means no citable source states it (or only a specification minimum); figures computed from it are left out too.

DMLS Ti-6Al-4V ELI Titanium is 3D printed: its properties depend on build direction and print settings; these are typical values.

Questions

Is Aluminum 6061-T6 stronger than DMLS Ti-6Al-4V ELI Titanium?

DMLS Ti-6Al-4V ELI Titanium is stronger: its yield strength is 1,100 MPa against 276 MPa for Aluminum 6061-T6 (3.99x).

Which is lighter, Aluminum 6061-T6 or DMLS Ti-6Al-4V ELI Titanium?

Aluminum 6061-T6 is lighter: 2,700 kg/m³ against 4,400 kg/m³ for DMLS Ti-6Al-4V ELI Titanium.

Which is stiffer, Aluminum 6061-T6 or DMLS Ti-6Al-4V ELI Titanium?

DMLS Ti-6Al-4V ELI Titanium is stiffer: Young's modulus 110 GPa against 68.3 GPa for Aluminum 6061-T6, so the same part in DMLS Ti-6Al-4V ELI Titanium deflects less under the same load.

Which is lighter for the same job, Aluminum 6061-T6 or DMLS Ti-6Al-4V ELI Titanium?

For the same stiffness or strength: Aluminum 6061-T6 is lighter for a stiff rod or tie (tension), stiff beam (bending), stiff panel or plate; DMLS Ti-6Al-4V ELI Titanium is lighter for a strong rod or tie, strong beam, strong panel or plate.

Part that must be	Aluminum 6061-T6	DMLS Ti-6Al-4V ELI Titanium
Stiff rod or tie (tension)	lighter	1% heavier
Stiff beam (bending)	lighter	28% heavier
Stiff panel or plate	lighter	39% heavier
Strong rod or tie	2.45x heavier	lighter
Strong beam	1.54x heavier	lighter
Strong panel or plate	23% heavier	lighter

For the same stiffness or strength, mass scales with density over stiffness (or strength) raised to a power set by how the part is loaded: 1 for a rod in tension, 1/2 for a beam in bending, 1/3 for a panel (the standard material-selection indices).

Which conducts heat better, Aluminum 6061-T6 or DMLS Ti-6Al-4V ELI Titanium?

Aluminum 6061-T6 conducts heat better: 167 W/m·K against 6.6 W/m·K for DMLS Ti-6Al-4V ELI Titanium.

Which expands less with temperature?

DMLS Ti-6Al-4V ELI Titanium expands less: 9 µm/m·K against 23.6 µm/m·K for Aluminum 6061-T6.

Among 59 materials

Stiffness against density

Strength against density