Advanced manufacturing Technology

We provide advanced manufacturing services in technologies like 3d printing, CNC machining, fabrication, extrusion, etc.

Experienced Engineers

Team of expert engineers with more than 15 years of experience.

on time project delivery

With locations in all over Australia we can assure lightning fast delivery.

Australia wide expandation

Zeal 3D is present in
Victoria, NSW, Western Australia,
Queensland and Tasmania.

ISO 9001-2015 certified

Committed to consistently provide products and services that meet customer and regulatory requirements and to demonstrate continuous improvement.

TITANIUM

Titanium is a unique and rare metal with a special blend of physical, chemical, and mechanical characteristics. Titanium metal is actually the ninth most common element in the universe. It is a silver-coloured metal that occurs naturally on earth. Titanium has a hefty price tag and needs to be made with specialised equipment and high-end 3D engineering practices. It is commonly extracted from different earth crustal minerals such as rutile, ilmenite, and sphene..

SERVICES OFFER BY ZEAL 3D IN TITANIUM

3D Printing

With the advantages of less material waste and the capacity to produce lightweight designs, titanium 3D printing is finding a niche in a variety of industries. When compared to conventional manufacturing techniques, 3D printing for titanium offers various benefits.

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With the acceptance of metal 3D printing as a practical production technique, titanium is being more widely used in sectors including medicine, automobiles, aerospace, defence and motorsports. Since titanium and titanium-based alloys offer higher mechanical strengths, weight-to-strength ratios, and corrosion resistance, they are ideal materials for 3D printed end products. Some of the 3D-printed titanium products are used as,.

Aerospace Industry - Wing and airframe structure, minor components such as rotors, compressor blades, and other turbine engine parts
Medical Industry - Orthopaedic devices like hip, spine, and knee implants
Automotive & Motorsports - Wheel rims, uprights, brackets, and brake callipers

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CNC Machining

Titanium seems to be the most highly regarded material in the CNC machining industry and even in manufacturing in general. Tools made of coated carbide that will withstand the alloy's stickiness and break up the lengthy chips are necessary for cutting titanium. To boost production and

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make up for the reduced feed per tooth, CNC machines can have more flutes. Utilising the appropriate and powerful equipment when working or machining with titanium is crucial. The very high torque in machines, which is necessary and may reach as high as 300–1500 Nm, is one of the recommendations for good machining processes for titanium. Furthermore, CNC machined parts for the aviation and medical industries frequently use titanium as a material. Common applications include:

Medical Screws
Medical Implants
Turbine Blades
Pacemaker Cases
Engine Components
Dental Implants

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3d Printing with titanium DMLS by Zeal3d

Fabrication

There are a number of factors that should be taken into account while using titanium, particularly during the design and fabrication phases, in order to maximise its potential. Compared to stainless steel, titanium is more likely to be formed when it interacts with other metals and with itself.

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If the essential stiffness, speed, and feed requirements are met, titanium can be easily shaped and fabricated. At temperatures that are typically a little lower than those used for steel, titanium and its alloys can be easily hot worked and fabricated. The methods used to press and hammer forge titanium are quite similar to those used to forge low-alloy steels. Some of the titanium products that are manufactured using the fabrication process are,

Custom Defence Products
Pressure Vessels
Heat Exchangers
Pipe & Fittings
Screw Threads
Bearing Surfaces

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Extrusion

Titanium extrusions are used in a variety of industries in order to produce customised and on-demand end-products. Especially, in the aircraft industry, titanium extrusions are used for a wide range of products, including titanium engine pylons and titanium seat tracks.

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In comparison to forging, extrusion has a variety of benefits. Smaller downstream machining, precise tolerances, and minimal waste are all advantages of custom-designed titanium products. In addition, extrusion dies are subjected to extreme heat and pressure, which results in inner erosion, often known as "die wash," which can lead to changes in dimensional tolerances. Usually, a fresh die is inserted for each item to maintain the tolerances. Following the extrusion of the forms, the downstream processes depend on the material. Some of the titanium extruded products are,

Engine Pylons
Titanium Tracks for Seats
Wing Slats
Nacelle Component
Flash Butt Welded Engine Rings
Door Lift Spline Gear

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INDUSTRIES SERVE IN TITANIUM

DEFENCE

Due to its exceptional corrosion resistance and high strength-to-weight ratio, titanium is one of the metals that is most frequently employed in military applications. Utilising titanium, manufacturers are able to produce Defence equipment that is lighter and more durable.

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It is used to create combat tanks and missiles in addition to structural elements for aircraft and armour protection, as well as various kinds of armament and pipelines (naval seawater).

Some of the popular grades of titanium used in the military industry are,

Ti-6A1-4V Alloy
Ti-6AL-4V ELI Alloy
6AL-6V-2Sn-Ti Alloy

Types of military components made with titanium are,

Aircraft Parts
Missiles
Armour Plating
Tank Armors
Aircraft Structural Components
Types Of Weaponry And Piping
Ordnance Equipment
Aircraft Turbines
Ordnance Frames
Landing Gears
Rocket Cases

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AEROSPACE

Since titanium sheet is highly resistant to cracking, corrosion, and fatigue, and has a high tensile strength to density ratio, as well as is able to sustain high temperatures, it is regarded as the optimum substance for the production of aeroplanes, missiles, and armour plating.

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It's used to make crucial structural components, including landing gear, exhaust ducts, firewalls, and hydraulic systems. In fact, titanium makes up close to half of the materials needed in an aircraft. The titanium alloy utilised in aerospace manufacturing also contains additional elements like aluminium, nickel, zirconium, and vanadium.

Some of the popular grades of titanium used in the aerospace industry are,

Ti-6Al-4V Alloy
Ti-8Al-1Mo-1V Alloy
Ti-6Al-2Sn-4Zr-6Mo Alloy
Ti-15V-3Cr-3Sn-3Al Alloy
Ti-10V-2Fe-3Al Alloy
Ti-5Al-2Sn-2Zr-4Cr-4Mo (Ti-17) Alloy
Ti-6Al-2Sn-4Zr-6Mo Alloy

Types of aerospace components made with titanium are,

Rotors
Compressor Blades
Hydraulic System Components
Nacelles
Airframe Parts
Airframe Wings
Landing Gear
Engine Parts

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MARINE

Since titanium resists corrosion, it is a perfect material for usage in the marine sector. Due to their resistance to corrosion in seawater, titanium alloys are used to create the hulks of naval ships. Additionally, titanium is utilised to make leads, drivers' knives, finishing lines,

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heat chillers for saltwater aquariums, heat exchanges, rigging, and propeller shafts. It is also utilised to house and house deployed monitoring and surveillance equipment in the water.

Some of the popular grades of titanium used in the marine industry are,

Ti-0.3Mo-O.8Ni
Ti-3Al-2.5V
Ti-3Al-2.5V-0.05Pd
Ti-6Al-4V
Ti-6Al-4 V ELI
Ti-6Al-4 V-0.05Pd
Ti-3Al-8V-6Cr-4Zr-4Mo

Types of marine components made with titanium are,

Plate Heat Exchanger
Tube Heat Exchanger
Tube Fittings
Water Inlet / Outlet Fittings
Fire Fighting Systems
Pipe Fittings, Support System
Pumps
Valves
Cone Stress Fittings
Submarine Pipeline

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AUTOMOTIVE

In the automobile sector, titanium sheet is especially used when low weight and high tensile stiffness are required. Given that metal is typically too expensive to be utilised in large quantities, it is also cost-effective. Because of its excellent strength and heat resistance,

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it is used to make exhaust and intake valves for engines. Due to titanium's strength, durability, lightweight, and heat and corrosion resistance, engine parts like connecting rods, valve retainers and springs, wrist pins, valves, rocker arms, and camshafts.

Some of the popular grades of titanium used in the automotive industry are,

Ti-6Al-4V
Ti-10V-2Fe-3Al
Ti-3Al-2V
Ti-4Al-4Mo-Sn-0.5Si
Ti-6242S
Ti-15V-3Cr- 3Al-3Sn
Ti-15Mo-3Al-2.7Nb-0.2Si
Ti-22V-4Al

Types of automotive components made with titanium are,

Valve Springs
Exhaust Systems
Valves
Steering Gear
Valve Retainers
Suspension Linkages
Rocker Arms
Torsion Bars
Driveshafts
Suspension Springs
Gearbox Housings
Cam Belt Wheels

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MEDICAL

Due to its bio compatibility, titanium has a prominent place in the medical sector. It is a non-toxic substance that has been used in numerous implants and surgical instruments. Titanium has been employed in the medical sector for a variety of applications, from dental implants

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to hip ball socket replacement. In addition, titanium is perfect for medical replacement structures like hip and knee implants since it is fully inert to bodily fluids. Titanium implants endure longer than those made of other materials because they actually encourage bone growth to cling to them. Today, it is also common to use mesh and titanium plates to support shattered bones.

Some of the popular grades of titanium used in the medical industry are,

Ti-6Al-4V ELI
Ti-6Al-7Nb
Ti-5Al-2.5Fe
Ti-6Al-4V
Ti-13Nb-13Zr
Ti-12Mo-6Zr-2Fe

Types of medical components made with titanium are,

Defibrillators
Pacemakers
Drug Pumps
Bone Growth Stimulators
Bone And Joint Replacement
Dental Implants
Neurostimulation Devices
Surgical Instruments

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JEWELLERY MAKING

Since it is strong and inert to life, titanium is becoming more and more common in the jewellery sector. People with allergies and those who live in humid environments prefer it because of its inertness. It is suitable for the production of wristwatches and watch cases

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due to its durability, dent resistance, low weight, and corrosion resistance. In addition, titanium is used by certain artists to create sculptures and other decorative items.

Some of the popular grades of titanium used in the jewellery making industry are,

Ti6Al4V
Ti6Al4V-2Sn
Ti6Al7Nb
Ti 6A4V F-136

Types of jewelleries made with titanium are,

Earrings
Necklaces
Bracelets
Rings
Brooches

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Grades of Titanium

Grades 1–4 of titanium are titanium alloys; the other grades are pure titanium. Due to its excellent corrosion resistance, pure titanium is employed, whereas alloys are preferred due to their extraordinarily high strength-to-weight ratio.

Grade 1 : Pure Titanium has high ductility and comparatively low strength.
Grade 2 : The most popular pure titanium, which has an ideal balance of ductility, strength, and weldability.
Grade 3 : The High strength Titanium that is employed in making Matrix-plates in shell and tube heat exchangers.
Grade 5 : The titanium alloy that is produced the most. It is extraordinarily strong and highly resistant to heat.
Grade 7 : It has superior resistance against corrosion in oxidising and reducing conditions.
Grade 9 : It has extremely high strength and resistance to corrosion.
Grade 12 : It is superior to pure titanium in heat resistance. The excellent corrosion resistance capability of this alloy makes it perfect for use in manufacturing equipment.
Grade 23 : It is the finest choice for any application that demands a blend of high strength, superior corrosion resistance, high toughness, and lightweight. In comparison to other alloys, it is more damage resistant.

WHY CHOOSE TITANIUM

1. High Strength

Pure titanium is distinguished by its exceptional tensile strength, which can reach 590 MPa. This strength significantly increases in alloy form, reaching 1250 MPa (as exhibited in Grade Ti-15Mo-5Zr-3AI alloy). Its fatigue strength is not affected by welding or being submerged in seawater, and it is roughly half as strong as its tensile strength. Titanium metal is an appropriate material for applications that call for a special blend of material strength and lightness.

2. Corrosion Resistance

Titanium is highly resistant to corrosion and is unaffected by air and water. Titanium is not corroded by aqua regia, nitric acid, less than 5% sulfuric acid, diluted alkaline solutions, or less than 7% hydrochloric acid when left out in the open. It can only be affected by concentrated hydrofluoric acid, hydrochloric acid, sulfuric acid, etc. Pure titanium naturally forms an oxide covering that protects it from corrosive substances and conditions because it quickly reacts with oxygen. It is resistant to corrosion caused by seawater, common acids, and high temperatures.

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3. Low Density

When compared to other metals on a dimensional basis, titanium metal has a significantly higher mill product cost due to its relatively low density, which is only 56% that of steel and 50% that of nickel and copper alloys. This low density translates to twice as much metal volume per weight. In addition to their higher strength capability, this obviously leads to manufacturing much lighter and smaller components for both static and dynamic structures.

4. Smooth Surface

Titanium material surfaces are smooth, non-corroding, and difficult to adhere to, and they keep their immaculate condition over time. In comparison to other metals, this surface encourages dropwise condensation from aqueous vapours, increasing condensation rates in coolers and condensers. Because of all of these benefits, titanium heat exchangers are smaller and have lower initial life cycle costs than those made of other typical technical alloys, making them more efficient and affordable.

5. Low Elastic Modulus

Titanium has an elastic modulus of 106.4GPa at room temperature, which is 57% greater than steel. This shows that titanium's capacity to withstand typical strain is lower than that of steel, limiting its applicability and making it unsuitable for rigid structural components. With rising temperatures, titanium's elastic modulus falls. The elastic modulus of titanium will be significantly reduced if the surrounding temperature is higher than 300 °C.

6. Strong Anti-Damping Performance

In comparison to copper and steel, titanium's vibration decay time is the longest after being subjected to mechanical and electrical vibration. This titanium's vibrating properties make it suitable for usage as a tuning fork, high-end acoustic speaker vibrating film, and medicinal ultrasonic pulverizer.

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WHY CHOOSE ZEAL 3D?

One-Stop Solution: Zeal 3D, an ISO 9001-2015 certified company, offers a wide variety of 3D engineering solutions, including 3D printing, CNC machining, laser cutting, vacuum casting, and CAD services, to help you achieve all of your organisational goals.

High-end Services: ZEAL 3D SERVICES provides a wide array of rapid prototyping services and technology to assist manufacturers and designers in creating and testing new products more rapidly, affordably, and safely. We can take your idea or design and bring it to reality in a matter of days by using tried-and-true fast prototyping technologies like 3D printing, vacuum casting, and CNC machining.

Extensive Material Support: To fully satisfy all of your 3D printing needs, Zeal provides a wide range of plastic and metal materials to achieve the desired end product. In order to print in more than 40 different 3D printing materials like copper, stainless steel, aluminium, and brass, we employ a number of 3D printing techniques, including FDM, SLS, SLA, SLM, DMLS, and Material Jetting. When it comes to titanium, Zeal 3D's DMLS metal technology can 3D print titanium-based products in layers as thin as 0.1 mm, with a minimum wall thickness as low as 1 mm.

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On-demand Services: Zeal 3D is the company to contact if you require custom, on-demand 3D printing services or other 3D engineering solutions. If you're looking for a 3D printing service in your neighbourhood, Zeal 3D is the best choice whether you need to generate a single prototype or a huge quantity of a product.

Instant Quoting: At Zeal 3D, we can transform your concept into a practical reality with the aid of our first-rate 3D engineering services. Get in touch with us right away for a quick, free quote based on your company's needs and those of your clients.

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Titanium Alloys

Metals that are composed of a combination of titanium and other chemical elements are known as titanium alloys. These alloys are extremely robust and have great tensile strength (even at extreme temperatures). They can sustain extremely high temperatures, have exceptional corrosion resistance, and are lightweight.

Titanium alloys are divided into three general types based on the metallurgical structure and overall titanium composition. These wide varieties of titanium alloys are used for various applications like 3D printing and 3D engineering services such as machine, milling, forming, and much more. Three types of titanium alloys are explained below.

Alpha Alloys

To increase the hardness and tensile strength of commercially pure titanium, it is alloyed with trace amounts of oxygen. By altering the amounts applied, it is possible to produce a variety of economically pure titanium grades with strengths ranging from 290 to 740 MPa. These substances are theoretically entirely alpha in structure, yet minute amounts of beta phase are possible if the beta stabilisers' impurity levels, such as those

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of iron, are sufficient. These alloys can't be heated up and are typically very weldable. They have fair-notch toughness, low to medium strength, a fair amount of ductility, and outstanding cryogenic characteristics. In addition, oxidation resistance and high-temperature creep strength are provided by near-alpha or strongly alpha alloys.

Beta Alloys

The other sort of titanium material is known as a beta alloy. When enough beta-stabilising elements are added to titanium, beta alloys can be produced. Although these materials have been around for a while, their appeal has just recently increased. They can be heat treated to high strengths, are easier to work hard than alpha-beta alloys, and some have better resistance to corrosion than commercially pure grades. In other words, beta or near beta alloys are often weldable, easily heat treatable, and have excellent strength up to intermediate temperature ranges. Cold formability is often quite good in the solution-treated condition.

Alpha-Beta Alloy

Alpha-Beta is a titanium alloy that is made up of two or more different metals. The result of this combination yields a product that is more durable than any of the parent components. Alpha-beta alloys are less formable than alpha alloys but have a higher strength and are heat treatable. With Alpha-Beta alloy, one can get fusion weld efficiency of up to 100%. These can be heat treated to varying degrees, and the majority of them can be welded with the possibility of some ductility loss in the weld area. They range from modest to high in strength. Although the properties of hot forming are good, cold forming frequently poses challenges. The majority of alpha alloys do not often have good creep resistance.

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Mining and Extraction Process of Titanium

The majority of the titanium used in the world is produced by mining and extracting heavy mineral sands. These sands are found below exposed igneous rock masses such as gabbro, norite, and anorthosite.
Such rocks contain minerals such as ilmenite, anatase, brookite, leucoxene, perovskite, rutile, and sphene that are titanium-bearing.
The titanium minerals in these rocks are least susceptible to weathering. By way of weathering, they become concentrated and are carried downstream as sand and silt grains.
They eventually become deposited along a continent's coastline as sand. This is where they are usually dredged or mined.
Additionally, mining is done in areas of the interior where deposits of titanium minerals from times when the sea level was greater than it is today are found.