Copper Beryllium Vs. Beryllium-Free Copper
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Copper Beryllium Vs. Beryllium-Free Copper MATERIAL MOLD Learning the advantages and disadvantages of each alloy coupled with adhering to safety measures can help your shop stay safe. Sherry L. Baranek oth copper beryllium and beryllium- Non-beryllium copper alloys — free copper producers are vehement developed as an alternative to copper Shop Talk B and adamant about why their beryllium — contain nickel, which also is on products are better and safer than the others the same list of hazardous substances. Recently MoldMaking Technology out there — and between MSDSs, However, non-beryllium alloy manufacturers magazine conducted an online poll to newspaper articles and media hype, point out that nickel is only a carcinogen in discover which alloy was more prevalent separating fact and fiction can be a fish, and when nickel is machined and in the shop. Forty-three percent of the confusing and time-consuming venture. ground, the particles do not become airborne, respondents reported that they use both Representatives from both sides of the as is the case with beryllium. copper beryllium and beryllium-free fence weigh in on the pros and cons of each So, what is a moldmaker to do when copper alloys, 43 percent only use alloy so you can make the right decision confronted with such a difference of beryllium-free copper alloys, and 14 about what is best for your shop. opinion on such a controversial topic? percent use copper beryllium exclusively. Beryllium — a silver-gray metallic Who is right and who is wrong? How can Copper beryllium alloy users cited element that occurs naturally in about 30 you be sure that the information out there better cooling properties and heat minerals — is lighter than aluminum yet is accurate? Unfortunately, there is not transfer qualities as the main reasons stiffer than steel. For the moldmaker, this enough evidence at this time to provide that they use these alloys. One respon- translates into efficient heat conduction and you with the “right” answer — but you can dent felt that “copper beryllium is harder faster cooling. However, this element can take a closer look at both sides of the story and stands up to the rigors of molding be hazardous to your health. According to to make a more educated decision. better.” Users of beryllium-free copper the Department of Energy (DOE) Training alloys noted safety and health concerns Reference for Beryllium Workers and Copper Beryllium over copper beryllium as the reason they choose beryllium free. Several Managers/Supervisors Participant Manual Nate Gildersleeve, director of technology respondents also felt that they achieved entitled Communicating Health Risks, for NGK Metals Corp. (Reading, PA) — a the same performance with beryllium- Working Safely With Beryllium, the most manufacturer of copper beryllium products free copper “without the problems.” significant disadvantage of beryllium as an — urges people to be cautious when dealing industrial material is the toxicity of its dust, with copper beryllium, but not to panic. “As fumes and soluble salts. And, unless venti- a rule, anything that is published — partic- lation and other controls are used, small ularly by manufacturers of competitive shouldn’t grind half of the material away particles and chips of insoluble beryllium- alloys — does not distinguish between and just let it get into the air because there containing materials break off during handling pure beryllium and something that may be one of those unlucky couple machining and other processes and spread contains less than one percent of beryllium. percent of people with ‘right’ allergy that through the air in the work area. People just see that name beryllium and it is will cause them to contract CBD. We still Inhalation of these tiny particles is the dealt with categorically. Even we actually have to be responsible about it, but we are type of exposure that can lead to chronic don’t make as much discrimination as is always looking for an appropriate way to beryllium disease (CBD) — an deserved between pure beryllium and a improve people’s understanding about irreversible and sometimes fatal scarring beryllium-containing alloy because we what the risks are and where they come of the lungs (see Warning Signs of want people to treat it with respect. from, and what’s the magnitude compared Chronic Beryllium Disease). On the other “The unfortunate effect — based on to what they are reading about. It’s hard to hand, all of the documented cases of CBD what’s been published and what the separate from all of this when the word thus far have dealt with the element in its competitive material manufacturers put out beryllium is in your name.” pure form — either as pure beryllium or there — is that respect has been replaced Carlos Cruz Wilson, a metals specialist pure beryllium compounds — and once by fear,” Gildersleeve continues. “It’s very for Houston, TX-based National Bronze beryllium is dissolved into copper, counterproductive for us. This is the heart and Metals, Inc. — a producer and distrib- beryllium comprises about 1.85 percent of of the subject, yet it’s appropriate to keep utor of a range of copper and copper alloys the alloy. people grounded in caution — they in various forms and shapes — also feels the public outcry over copper beryllium is mainly caused by ignorance. “The health Warning Signs of issues, although legitimate, can be controlled with the proper handling of the Chronic Beryllium Disease (CBD) beryllium alloys, or even the beryllium metal itself,” he states. “Only when CBD is primarily a lung disease, although it can affect other organs — like beryllium-containing materials are ground, sanded, polished, welded, EDM’d or the lymph nodes, skin, spleen, liver, kidneys and heart. It occurs in individ- changed — producing a dust, fume or mist uals who are “allergic” or sensitized to beryllium upon exposure. The long- — will there be any risk of exposure. term health effects can take years to develop after the first exposure to Turning, milling and drilling presently beryllium and there have been cases where people who were exposed to create no risk when done wet with the very small amounts of beryllium contracted CBD. proper coolant. “Only when these airborne particles are Symptoms of CBD may include the following: less than 10 microns in diameter are they able ➥ Persistent coughing. to penetrate the air sacs of the lungs, thus ➥ causing a high risk situation,” Wilson Fatigue. ➥ continues. “For beryllium to cause disease, Shortness of breath with physical exertion. the particles must penetrate the air sacs of the ➥ Blood in saliva and mucus that is coughed up. lungs with repeated exposure. The person ➥ Chest and joint pain. exposed also needs to be allergic to beryllium ➥ Loss of appetite. to get the disease, and statistics show that only ➥ Rapid heart rate. about three to four percent of the population is ➥ Fevers and night sweats. susceptible to the effects of beryllium.” Wilson adds that beryllium’s unique properties “give copper the strength of If you are experiencing any of these symptoms contact your physician. steel, with the conductivity of a copper alloy,” and allow the moldmaker to bring — From Communicating Health Risks, Working Safely With Beryllium heat energy into the old and dissipate that (published by DOE). energy very quickly. “The results are shorter cycle times, which leads to the ability to produce more parts and put more it’s in your flatware, stainless steel, etc., superior strength and conductivity of money in your pocket,” he affirms. and the copper alloys that compete with copper beryllium, if not better. “In addition, NGK Metals mandates that first-time beryllium copper contain higher levels of we have found that copper beryllium buyers of its copper beryllium read the nickel, but for whatever reason it just products are sensitive to heat,” he MSDSs and Speaking Out literature that doesn’t seem to get much attention.” comments. “In other words, some copper describe the risks of working with the alloy Cliff Moberg, president of Performance beryllium alloys lose hardness, tensile and and how these risks are managed. “In a Alloys (Germantown, WI) — a supplier of conductivity if it is heated above 600°F, nutshell, if you are set up to safely machine beryllium-free copper alloys for use in where our product is unaffected to temper- metals, you also can safely machine constructing cavities, cores and inserts, as atures in excess of 900°F.” beryllium copper,” Gildersleeve states. well as other applications — refutes the Moberg also contends that copper “There isn’t a lot of dry grinding that goes aforementioned statement. “While nickel beryllium producers use a number of on out there for making a finished machine is a listed carcinogen, the human exposure tactics to steer potential users toward their part, or the kinds of operations that put fine methods vastly differ for the elements product and mask the alloy’s contents that particles into the air. We do caution beryllium and nickel,” he explains. “The could be termed questionable. “The most moldmakers against torch cutting pieces — risk to humans with nickel is through obvious example is that they publish to cut into larger pieces they should be using ingestion of contaminated fish and copper beryllium’s ultimate properties a saw. We make precautionary statements seafood caught from nickel-contaminated instead of the average numbers to compare and we are liable and required to put some waters. Those contamination arenas were their products,” he says. “Our competitors very stringent warning labels on the material common in the days of industrial waste publish their numbers on a higher scale as well to protect against misuse. dumping prevalent in years past. while we publish our nominal numbers — “The non equitable facet to this that’s Additionally, since nickel is a heavy taking their very best properties and always amazed me is that there have been metal, the particles do not become publishing them instead of publishing the arguments for some time about how to airborne like beryllium,” he points out, typical mean (most often attainable) characterize the health hazards of “and there is no known direct connection numbers that we do.