Titanium Bar Sizes and Dimensions: Complete Guide
Titanium bars are essential materials across aerospace, marine, medical, and industrial sectors. Their strength-to-weight ratio, corrosion resistance, and long-term durability make them a top choice for demanding applications. However, selecting the right titanium bar size and dimension is just as important as selecting the right grade. The proper dimension ensures optimal performance, structural integrity, and cost-efficiency.
In this complete guide, sakyalloy walks you through the standard and custom sizes of titanium bars, dimensional tolerances, and the factors that influence your selection process.
What Is a Titanium Bar?
A titanium bar is a solid, long piece of titanium metal available in several cross-sectional shapes—primarily round, square, rectangular (flat), or hexagonal. These bars are either hot-rolled, cold-drawn, or forged, and come in different surface finishes and grades depending on their application.
sakyalloy offers titanium bars in a wide variety of dimensions and tolerances, serving industries such as aerospace, medical, petrochemical, and energy.
Common Types of Titanium Bars by Shape
Titanium bars are classified not only by size but also by cross-sectional geometry. Here are the most common types:
1. Round Bar
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Most widely used shape
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Commonly used in medical implants, fasteners, and aerospace components
2. Square Bar
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Suitable for CNC machining and structural applications
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Used in high-precision mechanical parts
3. Rectangular (Flat) Bar
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Ideal for support components, brackets, and spacers
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Used in architectural and marine hardware
4. Hexagonal Bar
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Preferred for components requiring wrenching or threading
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Often used in valves, bolts, and nuts
At sakyalloy, all bar shapes are available with tight dimensional control and full certification.
Standard Titanium Bar Sizes
While titanium bars can be manufactured to custom dimensions, there are standard sizes that dominate global markets.
Round Bar Sizes
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Diameter: From 3 mm up to 300 mm
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Length: Typically 1000 mm to 6000 mm (custom lengths available)
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Common diameters: 6 mm, 10 mm, 12.7 mm (½”), 25.4 mm (1″), 50 mm, 75 mm, 100 mm
Square Bar Sizes
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Side width: From 6 mm to 100 mm
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Length: 2000 mm to 4000 mm standard
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Custom milling or centerless ground upon request
Rectangular/Flat Bar Sizes
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Thickness: 3 mm to 50 mm
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Width: 10 mm to 200 mm
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Length: Up to 6000 mm
Hex Bar Sizes
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Across flats (AF): 5 mm to 80 mm
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Length: Typically 3000 mm or 4000 mm
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Available in Grade 2 and Grade 5 commonly
sakyalloy maintains a large stock of standard sizes for fast shipment and also supports made-to-order dimensions for OEM clients.
Dimensional Tolerances
Dimensional accuracy is crucial for many high-precision applications. Titanium bar tolerances are typically defined by ASTM or AMS standards, depending on the application.
Round Bars (Cold Drawn)
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Tolerances: h9, h10, or tighter on request
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Surface Finish: Centerless ground or polished
Hot Rolled Bars
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Larger diameter range
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Looser tolerance compared to cold-drawn
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Typically used for forging and rough machining
Flat and Square Bars
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Thickness and width tolerance per EN10058 or ASTM B348
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Custom tolerances upon request for CNC or aerospace use
All sakyalloy titanium bars undergo dimensional inspection before delivery and are supplied with full compliance documentation.
Surface Finishes Available
The surface condition of a titanium bar affects its corrosion resistance, appearance, and further processing suitability.
Common surface finishes include:
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Hot rolled black finish (for general machining)
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Pickled finish (removal of oxide layer)
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Polished or ground finish (for medical, aerospace, or decorative applications)
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Bright drawn (tight tolerance with smooth surface)
sakyalloy offers bars with custom surface treatment, depending on the end-use environment.
Packaging and Length Options
To meet global shipping requirements, sakyalloy provides various length and packaging options:
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Standard length: 3000 mm / 4000 mm / 6000 mm
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Cut-to-length service available as per customer requirements
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Bundled packaging with end caps for round bars
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Wooden crate packaging for export and protection against moisture and impact
Each titanium bar is labeled with grade, heat number, and size for traceability.
Grade and Size Compatibility
Not all titanium grades are available in all sizes due to manufacturing constraints. Here’s a general guideline:
| Grade | Common Diameter Range | Notes |
|---|---|---|
| Grade 1 | 6 mm – 150 mm | Soft and ductile |
| Grade 2 | 4 mm – 200 mm | Most widely available |
| Grade 3 | 10 mm – 100 mm | Less common |
| Grade 4 | 6 mm – 100 mm | High strength |
| Grade 5 (Ti-6Al-4V) | 6 mm – 300 mm | Aerospace and medical |
sakyalloy provides expert assistance in matching grades to suitable sizes and shapes based on your project specifications.
Applications Based on Bar Size
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Small diameter bars (6–25 mm): Medical pins, orthopedic screws, aerospace fasteners
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Medium diameter bars (30–100 mm): Chemical processing shafts, marine fittings
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Large diameter bars (100–300 mm): Aerospace forgings, rings, industrial rollers
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Flat bars: Heat exchangers, valve bodies, support structures
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Square/hex bars: Fasteners, precision components, custom CNC parts
With a broad inventory, sakyalloy serves all of the above industries with matching titanium bar dimensions.
How to Specify a Titanium Bar for Your Project
To order the correct titanium bar, provide the following details:
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Grade (e.g., Grade 2, Grade 5)
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Shape (round, square, flat, hex)
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Size (diameter/width × length)
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Surface finish (black, pickled, polished)
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Quantity required
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End-use application
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Standards required (e.g., ASTM B348, AMS 4928)
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Test certification (3.1, 3.2, NADCAP if needed)
sakyalloy can also assist with full machining, cutting, and finishing to drawing.
Quality Control and Documentation
All titanium bars from sakyalloy are subjected to rigorous testing:
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Ultrasonic testing (UT)
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Mechanical tests (tensile, yield, elongation)
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Hardness and straightness checks
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Visual and dimensional inspection
Certification includes:
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EN 10204 3.1 / 3.2
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ASTM B348, ASME SB348, ISO 5832-3
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Material Test Report (MTR) with chemical and mechanical properties
Conclusion
Titanium bars are available in a wide range of sizes, shapes, and grades to serve diverse industries. Selecting the right size is not just about dimensions—it involves understanding application needs, material performance, and fabrication methods. From tiny surgical pins to large industrial shafts, sakyalloy has the solution.
With in-house machining, testing, and export packaging capabilities, sakyalloy delivers titanium bar products that meet international standards and customer expectations.