|
 |
Beryllium is an unusual material in that its applications
are both very unique, but also quite common. Beryllium metal satellite
structures, space telescope mirrors, and military targeting systems
are on the “unique” application side. Electronic connectors
for the on-board computers under the hood of the family automobile,
golf club heads, fire-suppressing sprinkler head components, and jewelry
substrates are among its more common commercial alloy uses.
 |
Vacuum Cast Metallic Beryllium
|
 |
Ultra-Precision Beryllium Guidance
Component
|
 |
| Beryl - Beryllium Containing Raw
material |
Pure metallic beryllium is number four in the periodic table of elements and is one of the lightest
structural metals available. Its density is one third less than aluminum
and is approximately six times stiffer than steel by weight. As a structural
material its applications range from high reliability strategic guidance
and infra-red targeting systems components used in military applications
to complex instrument housings, ultra-precision satellite components
and optical substrate elements for the Hubble Space Telescope.
Historically,
applications for metallic beryllium centered on complex machined components
and structures for sophisticated military and aerospace systems.
The emerging technologies fostered
by military and space programs post World War II often required extremely
precise, jewel-like machined parts. Instruments and devices operating
in demanding performance environments like the extremes of cryogenic
cold in outer space and the high temperature excursions of lift-off
and re-entry require an “engineered” material with the unique
properties of metallic beryllium.
Complex beryllium optical substrates
and structures provide the stability and precise dimensional characteristics
required for optical systems used in ultra-accurate / ultra-capable
military targeting systems. Beryllium optical substrates were utilized
in telescope mirrors for the unusual “faceted-mirror design”
for Hawaii’s Keck Observatory. Many military and commercial reconnaissance
satellites, and a wide variety of NASA space scientific and exploration
missions utilized metallic beryllium structural elements. The material’s
unique nuclear properties (reflects neutrons, transparent to x-rays)
have resulted in applications in nuclear test reactors and x-ray windows
for mammography machines.
Metallic beryllium is
manufactured utilizing powder metallurgy processes. Beryllium values
are extracted from beryllium-bearing ores like bertrandite (relatively
low beryllium content) or beryl (relatively higher beryllium content).
The resultant beryllium hydroxide concentrate is further processed to
obtain pure metallic beryllium in the form of “pebbles”
which are subsequently reduced to fine powder for compaction to full
density by heat and pressure. Pure beryllium products are divided into
metallic structural materials and beryllium-oxide ceramic materials.
In addition to the applications described above for metallic beryllium,
the ceramic form of the material is also involved in high technology
system. Ceramic beryllium exhibits both high thermal conductivity and
is high electrical resistivity. It is extremely stable and can be formed
to near-net shape configurations. Sophisticated electronic devices and
applications are the primary use area regarding beryllium-oxide ceramics.
 |
| Hot Isostatic Pressed Beryllium |
Relative to beryllium containing alloys, comparatively small additions of pure metallic
beryllium ranging from .50 percent up to 2.75 percent significantly
enhance the performance properties and characteristics of both copper
and nickel materials. Beryllium copper alloys are materials with exceptional
strength, thermal and electrical conductivity and outstanding wear resistance.
Beryllium copper is also a harden-able copper alloy, i.e. mechanical
properties can be varied based on the solution annealing and aging processes
utilized.
Cast beryllium copper components are manufactured by investment, sand, pressure, centrifugal,
and die casting processes in foundries around the world. Permanent and
ceramic molds are also utilized. Relative to foundries, beryllium copper
has been melted and cast into a wide variety of component parts ranging
from miniature electrical connectors to large weld gun structural members
used in automotive assembly line robots.
Wrought forms of beryllium copper (rod, bar, plate, tube) are produced utilizing essentially
the same chemical composition format, but are manufactured either by
cold or hot working processes such as forging, extrusion, drawing, and
rolling.
Here are a few facts about beryllium
containing alloys:
Beryllium containing
alloys, like many industrial materials, may present a health
risk if handled improperly. The inhalation of particulate (dust, fume,
mist, fragments, particles and/or powder) containing beryllium can cause
a serious lung condition in some individuals. The degree of hazard can
vary, depending on the form of the product, how it is produced and handled,
as well as the amount of beryllium in the product. Product specific
Material Safety Data Sheet (MSDS) are important sources of information
for additional environmental, health, and safety data. It is imperative
this information is carefully reviewed and clearly understood prior
to working with any beryllium containing alloy or material.
Environmental and Safety information is generally applicable
to all forms of beryllium materials. This applies to all the beryllium
containing alloys and their various product configurations including
casting and master alloys, as well as, wrought products such as strip,
wire, rod, bar, plate, and tube. Characterization of worker exposure
studies, including air monitoring, should be conducted for operations
where a potential for exposure to the various forms of beryllium particulate
exists. Air monitoring is the primary method for determining the degree
of exposure and effectiveness of facility engineering and work practice
controls. Consult with an experienced industrial hygienist regarding
beryllium and beryllium containing materials or contact Freedom Alloys,
Inc. for information at 800-373-3251 toll free, 610-792-3202.
|
