To meet the need of large-scale damage tolerance titanium alloy for new generation fighter, this paper examines the TC4-DT titanium alloy’s composition and macrostructure control of large-scale bar and forging stock, the microstructure control during heat treatment process of large-scale forgings, the manufacturing process control of material and forgings, and the fatigue strengthening of parts. The results of large-scale ingot melting, large-scale bar and forging stock trail production, heavy section forging trail production, and structural design and manufacture show that the damage tolerance titanium alloy TC4-DT’s composition of large-scale ingots is homogeneous and the tensile strength coefficient variation of large-scale forging stocks and heavy section forgings can be reduced to about 2%. The impacts of laser shock peening, shot peening, and cold extrusion have remarkable life increment of the titanium alloy. The damage tolerance titanium alloy TC4-DT has been widely applied on new generation fighters.
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