Is Beryllium Copper Safe? Machining and Handling per Materion's Guidance

Where does the risk with beryllium copper come from?

The main risk comes from particulate created by processing, not from using solid parts as supplied. Materion's SDS says exposure by inhalation, ingestion and skin contact can occur when melting, casting, dross handling, pickling, chemical cleaning, heat treating, abrasive cutting, welding, grinding, sanding, polishing, milling, crushing, or otherwise heating or abrading the surface in a way that generates particulate. The SDS lists the material's hazards as:

• May cause an allergic skin reaction
• May cause allergy or asthma symptoms or breathing difficulties if inhaled
• Causes damage to organs (respiratory system) through prolonged or repeated inhalation
• May cause cancer

The SDS also covers chronic beryllium disease (CBD), a lung condition that can develop in some individuals, and notes that specific genetic factors make some people more susceptible. The medical information is in sections 4 and 11 of the SDS; if exposed or concerned, the SDS advises getting medical advice.

How should beryllium copper be machined?

Control particles at the source. Materion's SDS says machining is usually done under a liquid coolant flood, which helps reduce airborne particulate, but fine particulate building up in recirculated coolant can become airborne, so the coolant should be filtered and kept from splashing onto floors or clothing. Sanding and grinding may need complete hooded containment and local exhaust ventilation.

• Ventilation: local exhaust ventilation is the preferred control, with the inlet as close as possible to where particles are generated, no fans disrupting the airflow, and regular checks.
• Cleaning: use HEPA-filtered vacuums and wet methods; never compressed air, brooms or ordinary vacuum cleaners, which put particles back into the air.
• Work practice: clean loose particulate off parts between steps, keep contaminated work clothing at the workplace, wash hands before eating or smoking, and do not eat, drink or smoke while working.
• Protective equipment: gloves, and safety glasses or a face shield where dust, mist or fume is present. Where ventilation is inadequate, respirators specified by an industrial hygienist or other qualified professional, with fit testing and training.

Can beryllium copper molds be welded or repaired?

Yes, with welding fume controlled per the SDS, since welding is one of the processes the SDS lists as generating particulate. Materion offers WeldPak and WeldPak XL filler metal for TIG repair of beryllium copper MoldMAX molds. Note that MoldMAX HH and PROtherm are beryllium copper, while MoldMAX V and MoldMAX XL are not.

Which grades does this guidance cover?

It covers the wrought grades this SDS lists: C17200, C17510, C17410, C17460 and MoldMAX/PROtherm. Cast alloys have their own SDS, so always use the SDS that matches the product. All grades are on the beryllium copper page.

Which rules or exposure limits apply?

Follow the occupational health rules where you work and the values in the current SDS. Materion's SDS collects exposure limits from several agencies, and Materion recommends that users reduce airborne beryllium exposure to the lowest feasible level, beyond simply complying with regulation. Materion publishes more on its environmental, health and safety page and at berylliumsafety.com.

In short: ask your supplier for the current SDS before any work starts, and have your plant's safety lead set the controls from it.