Aluminum 7075 is significantly cheaper and easier to machine, making it the default for non-critical aerospace structures. Titanium Grade 5 wins when maximum strength-to-weight, temperature resistance, or corrosion resistance is non-negotiable.
| Property | Aluminum 7075-T6 | Titanium Grade 5 (Ti-6Al-4V) |
|---|---|---|
| Tensile Strength | 572 MPa (83 ksi) | 950 MPa (138 ksi) |
| Yield Strength | 503 MPa (73 ksi) | 880 MPa (128 ksi) |
| Hardness | 150 HB | 334 HV |
| Density | 2.81 g/cm³ | 4.43 g/cm³ |
| Machinability Rating | 70/100 | 22/100 |
| Thermal Conductivity | 130 W/m·K | 6.7 W/m·K |
| Melting Point | 477–635 °C | 1,604–1,660 °C |
| Tolerance | ±0.005 mm | ±0.01 mm |
| Property | Aluminum 7075-T6 | Titanium Grade 5 (Ti-6Al-4V) | Winner |
|---|---|---|---|
| Strength-to-Weight | 203 kNm/kg | 214 kNm/kg | Titanium |
| Machinability | 70/100 | 22/100 | Aluminum |
| Cost per Part | 1x (baseline) | 5-10x | Aluminum |
| Corrosion Resistance | Good | Excellent | Titanium |
| Max Service Temp | 120°C | 315°C | Titanium |
| Density | 2.81 g/cm³ | 4.43 g/cm³ | Aluminum |
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