Core Principle

This is a choice between "ultimate performance at high cost" (Titanium) and "excellent performance at moderate cost" (Aluminum).

Performance Comparison (Ti-6Al-4V vs Al 7075-T6)

• Strength-to-Weight Ratio: Titanium ~60% better than 7075 Aluminum
• Stiffness: Titanium 1.6x stiffer (higher Young's Modulus)
• Temperature Resistance: Titanium >400°C vs Aluminum <150°C
• Cost: Titanium often 5-10x total cost of aluminum

Selection Guidelines

Choose 7075 Aluminum for most high-performance applications.

Consider Titanium only when:
• Part must operate at high temperatures (>150°C)
• Stiffness requirements exceed aluminum limits
• Weight is absolutely critical and cost is secondary