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6al-4v is Gr5...yup. What's really impressive about it are how minimal the differences are between forged and cast for component use.
Regardless, vibaration/resonance will be what causes the weld to fail, with my guess. Old Greg's idea for testing actually isn't bad. Now to keep in mind, the exhaust isn't (or shouldn't be) rigid mounted. So a flex section/bellows will allow it to wobble/swing and then is is still suspended by rubber or poly exhaust hangers. I wouldn't worry over cracks is overkill for anything behind the flew section. The exhaust manifold which is rigid mounted to the engine (a large vibrating unit) where the pipes are growing in multiple axis', that is where your concern for ti tubing weld failures should be IMO...see usage of slip joints and bellows.
I plan to play with some 2xxx series alum for the catback. Probably 2024. It costs was less than ti and does reasonably well with heat.
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