Safety Practices for Machining Beryllium Copper

(Drilling, Boring, Milling, Turning, Tapping, Reaming and Sawing)

Beryllium copper, in solid form and as finished parts, presents no particular health hazard. In addition, most manufacturing operations conducted properly on well-maintained equipment are capable of safely processing beryllium copper. Like many industrial materials, it poses a health risk only if mishandled. Breathing very fine particles may cause a serious lung condition in a small percentage of individuals. Risk from processes generating fine particulate can be minimised with simple, proven, and readily available engineering controls such as ventilation.

There is no particular health risk associated with beryllium copper skin contact (although some people may have a sensitivity to copper). A cut or laceration received from a sharp edge has no increased infection risk because of the beryllium copper. Routine first aid treatment is adequate for minor cuts. Beryllium copper contact with the mouth or food is similarly not a special problem, since the only known special hazard associated with the metal is breathing very small particles.

To be hazardous, airborne particles must be less than about 0.0005 inch to 10 microns in diameter. Particles in this size range are not visible to the unaided eye; thus the large, readily visible particles of most machining operations are not an inhalation hazard. Large particles do not remain airborne; and if they are inhaled, they are removed before they enter the small branches of the lungs.

Beryllium copper machining, that generates large particles, is usually performed in an open shop environment with no unusual ventilation or housekeeping requirements. Unless workers are exposed to fine particulate in a manner that is not controlled by ventilation, there is no need for protective clothing. As-cast or heat treated parts with surface scale should be machined with ventilation to prevent the scale from spalling and becoming airborne. Common housekeeping practices, such as wet vacuuming instead of blowing dust from equipment or floors, and keeping work areas dust free, are very effective in providing a clean, safe workplace.

Beryllium copper is a ductile metal that machines easily, producing generally large chips and turnings. Machining operations such as drilling, boring, milling, turning, tapping, reaming, and non-abrasive sawing, that typically generate large chips, pose no significant exposure risk. These are also machining operations where the liquid lubricant/coolant and the relatively slow tool speed prevent chips from becoming an airborne hazard. Machining lubricant should be filtered, settled, or centrifuged, or changed regularly to prevent accumulation of any fine particles. The recycling of unfiltered lubricant/coolant can increase the beryllium exposure potential during machining.

If no lubricant or coolant is used during machining and there is no concern about the possibility of airborne dust, then local ventilation can be used at the point of the operation to control the dust. The ventilation duct should be positioned close to the tool and in-line with the direction of the generated chips. A portable ventilation system can be used in a shop where beryllium copper is machined infrequently on several pieces of equipment. To be effective, the ventilation system must have a regular maintenance program by a knowledgeable person.

Beryllium copper machining scrap is not hazardous. Its disposal procedure is the same as other common metals such as brass, steel, or aluminum. Lubricant or oil removal should be performed and may be required before landfill disposal. However, if properly segregated from other metals, your beryllium copper scrap can be valuable. Brush Wellman purchases clean scrap (routine amounts of lubricant are not a problem), for recycling, at a premium above mixed copper alloys. If there is a concern about the safety of these operations in your shop, consult an industrial hygienist who can measure the air concentrations during the machining operations. Most hygienists can also recommend equipment and procedures to allow you to perform these operations safely.

This information applies to a specific manufacturing operation. If you need additional information on safe handling practices or technical data on beryllium products, contact Instrument Specialties Delaware Water Gap P.O. Box 650, Shielding Way Delaware Water Gap, PA 18327 Tel: +1.570.424.8510 Fax: +1.570.424.6213

All material presented courtesy of
Brush Wellman, Inc., Cleveland, Ohio and
Instrument Specialties Company Inc., Delaware Water Gap, PA.