Beryllium copper still raises questions of safety

Use caution when creating dust from this metal, but know its cycle time advantages when used properly.

Even now, beryllium copper periodically sounds alarm bells in mold shops over safety concerns when machining this metal. In one instance, moldmakers in a shop who had read an online report about the hazards of machining beryllium walked off the job until they were assured that their work could be done safely.

Nate Gildersleve, director of technology for NGK Metals Corp. (Sweetwater, TN), and Cliff Moberg, president of Performance Alloys (Germantown, WI), addressed the topic of beryllium copper in “What the (bleep) Do We Know About Beryllium Copper?” at this year’s Annual Convention of the American Mold Builders Assn. held in Key West, FL.

On the plus side, beryllium copper is used to counter stress that aluminum can’t handle, or heats that steel can’t take. It’s an excellent heat dissipater, and a reduction in cycle time equals a reduction in manufacturing costs.

However, it’s not always the metal of choice. Nate Gildersleve stressed the importance of choosing a mold metal intelligently. Metal is selected based on required properties. There is a trade-off, of course. As hardness increases, conductivity decreases. Beryllium copper is used in a variety of products such as aircraft bushings, welding equipment, and so forth, but it should be used only where these specific properties are essential to the application—i.e., where hardness is required.While the dangers of beryllium dust have been well publicized, Gildersleve added that shops shouldn’t ignore safety standards of any metal. “The number one source of beryllium is in windblown dust,” he said. “Electric utilities are the second largest source, and industrial uses are number three. Beryllium is everywhere. But you should never grind any metal to a fine powder and breathe it in.

“Don’t be afraid of beryllium copper. Be in control.”

Moberg explained that safe handling of beryllium copper alloys is possible, but that shops still need to follow OSHA and NIOSH regulations and handling and disposal recommendations. “Many companies either ignore or believe there isn’t really a problem [with beryllium copper alloys],” said Moberg. “Or they believe their exposure is minimal. However, it will be the next asbestos with respect to liability in the workplace.” (See “Safety Tips for Machining Beryllium Copper,” below)

Offering a highly conductive alternative, Performance Alloys produces a beryllium-free copper alloy for mold component fabrication. In producing cores from copper alloys, Moberg found that 90% of the heat removal from the molded parts occurred from contact with the core surfaces of the mold. He says using copper alloys can result in a 20% to 30% reduction in mold cycles in the most conservative sense; 50% or greater is possible if you’re willing to push the envelope.

“This is an advantage you can take to your customers who are thinking about taking products off shore,” Moberg said. “They use these materials very little in China.”