Beryllium
Beryllium (Be) is a light, stiff metal. As an alloying addition of about 2%, it makes copper as hard as steel while still conducting well. Warning: beryllium and its compounds are toxic and carcinogenic – dust and fumes must not be inhaled.
What is beryllium
Beryllium (Be) is a light metal – stiff, strong, and very light. You seldom run into pure beryllium in the workshop, but as an alloying element it's important: just about 2% beryllium in copper gives an alloy that can match steel in strength and hardness and still conducts electricity well.
Why beryllium copper is special
Beryllium copper (CuBe) can be hardened like steel: after solution annealing and quenching, it's soft and formable; after aging, it reaches full hardness. That's why it's used in springs, connectors, spark-free tools, and mold inserts where high strength plus conductivity are needed.
The hazard when machining
Beryllium isn't a problem as long as the part stays cold. It gets dangerous when beryllium-containing dust or fumes are generated – during grinding, welding, brazing, or polishing. The fine dust gets into the lungs and can trigger berylliosis, a chronic lung disease. Beryllium and its compounds are considered carcinogenic.
Workshop rules
• Work on beryllium-containing materials only with extraction and suitable respiratory protection.
• Pick up dust wet or with an industrial vacuum (class H), never blow it up with compressed air.
• Wash work clothes separately, clean hands thoroughly before eating.
• For occupational exposure limits and protective measures, TRGS 900 and the Hazardous Substances Ordinance (GefStoffV) apply – if in doubt, consult the safety specialist.