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Page 1: Guide to Copper Beryllium - · PDF fileBrush Wellman is the leading worldwide supplier of High Performance Copper Alloys, including Copper Beryllium. We provide manufacturing excellence
Page 2: Guide to Copper Beryllium - · PDF fileBrush Wellman is the leading worldwide supplier of High Performance Copper Alloys, including Copper Beryllium. We provide manufacturing excellence

Brush Wellman is the leading worldwide supplier of High PerformanceCopper Alloys, including Copper Beryllium. We provide manufacturingexcellence in the form of high reliability products and services to satisfy ourcustomers’ most demanding applications. We provide these services in aculture of local support and global teamwork.

© 2002Brush Wellman Inc.

Cleveland, Ohio

Guide to Copper Beryllium

strip

rod

wire

bar

tube

plate

Page 3: Guide to Copper Beryllium - · PDF fileBrush Wellman is the leading worldwide supplier of High Performance Copper Alloys, including Copper Beryllium. We provide manufacturing excellence

2

Product Guide - Strip

Alloy Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Wrought Alloys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Wrought Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Physical Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Product Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Temper Designations . . . . . . . . . . . . . . . . . . . . . . . . . . 9Mechanical and Electrical Properties. . . . . . . . . . . . . . 10Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Stress Relaxation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Rod, Bar and Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Plate and Rolled Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Forgings and Extrusions . . . . . . . . . . . . . . . . . . . . . . . . . 20Drill String Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Other Products and Services . . . . . . . . . . . . . . . . . . . . . 22

Engineering Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Heat Treatment Fundamentals. . . . . . . . . . . . . . . . . . . . 24

Phase Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Cold Work Response . . . . . . . . . . . . . . . . . . . . . . . . . 25Age Hardening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Microstructures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Cleaning and Finishing. . . . . . . . . . . . . . . . . . . . . . . . . . 30Joining-Soldering, Brazing and Welding. . . . . . . . . . . . . 31Machining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Hardness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Fatigue Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Corrosion Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Other Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Your Supplier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39This is Brush Wellman . . . . . . . . . . . . . . . . . . . . . . . . . 40

Company History. . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Corporate Profile. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Mining and Manufacturing.. . . . . . . . . . . . . . . . . . . . . . 41Product Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Safe Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Content

Page 4: Guide to Copper Beryllium - · PDF fileBrush Wellman is the leading worldwide supplier of High Performance Copper Alloys, including Copper Beryllium. We provide manufacturing excellence

AlloyGuideWrought Alloys 4Wrought Products 5Physical Properties 6

The copper beryllium alloyscommonly supplied in wroughtproduct form are highlighted in thissection. Wrought products are those inwhich final shape is achieved by workingrather than by casting. Cast alloys are describedin separate Brush Wellman publications.

Although the alloys in this guide are foremost in the line thathas established Brush Wellman’s worldwide reputation for quality,they are not the only possibilities. We welcome the opportunity to workwith you in selecting or developing an alloy to make your application succeed.

3

Page 5: Guide to Copper Beryllium - · PDF fileBrush Wellman is the leading worldwide supplier of High Performance Copper Alloys, including Copper Beryllium. We provide manufacturing excellence

Brush Wellman manufactures copper beryllium inseveral distinct compositions. These fall into twocategories: alloys selected for high strength (Alloys 25,190, 290, M25 and 165) and alloys selected for highconductivity (Alloys 3, 10, 174 and Brush 60®). Alloy390™ combines both attributes, high strength andhigh conductivity.

Brush Alloy 25 is the most commonly specified copperberyllium and is available in the wrought forms listedon page 5. In its age hardened condition, Alloy 25attains the highest strength and hardness of anycommercial copper base alloy. The ultimate tensilestrength can exceed 200 ksi, while the hardnessapproaches Rockwell C45. Also, in the fully agedcondition, the electrical conductivity is a minimum of22% IACS (International Annealed Copper Standard).Alloy 25 also exhibits exceptional resistance to stressrelaxation at elevated temperatures.

Brush Alloy 190 is a mill hardened strip product. Inother words, the strip is age hardened to a specifiedstrength level as part of the manufacturing process atBrush Wellman prior to shipment. This alloy is similarto Alloy 25 in chemical composition. Alloy 190 issupplied with tensile strength up to 190 ksi andRockwell hardness to C42. Cost effectiveness isrealized by elimination of age hardening and cleaningof stamped parts.

Brushform® 290 is a mill hardened strip product that issimilar in strength properties and composition to Alloy190 but exhibits improved formability. Componentreliability and fabrication considerations may require ahigh strength material with good formability. Theimproved strength/formability relationship ofBrushform® 290 makes it a cost effective alternative to conventional mill hardened product for such applications.

Brush Alloy M25 offers the strength properties of Alloy25 with the added benefit of being “free machining”.Alloy M25 rod and wire contain a small amount of leadto provide an alloy tailored for automatic machiningoperations. Lead promotes formation of finely dividedchips thus extending cutting tool life.

Brush Alloy 165 contains less beryllium than Alloy 25and has slightly lower strength. It is less expensive thanAlloy 25 and may be substituted when strength is lessdemanding. Alloy 165 is available in wrought productforms in annealed and aged tempers.

Brush Alloys 3 and 10 combine moderate yieldstrength, up to 140 ksi, with electrical and thermalconductivity from 45 to 60 percent of pure copper.Alloys 3 and 10 are available in wrought product formsand can be supplied fully hardened. Hardenedproducts are identified by the temper designation ATor HT, and have good formability.

Wrought Alloys

4

Alloy Guide

CopperAlloy Cobalt

Brush UNS Cobalt + NickelAlloy Number Beryllium Cobalt Nickel + Nickel + Iron Lead Copper

25190 C17200 1.80-2.00 _ _ 0.20 min 0.6 max 0.02 max Balance290

M25 C17300 1.80-2.00 _ _ 0.20 min 0.6 max 0.20-0.6 Balance

165 C17000 1.60-1.79 _ _ 0.20 min. 0.6 max _ Balance

3 C17510 0.2-0.6 _ 1.4-2.2 _ _ _ Balance

10 C17500 0.4-0.7 2.4-2.7 _ _ _ _ Balance

60 C17460 0.15-0.50 _ 1.0-1.4 _ _ _ Balance

174 C17410 0.15-0.50 0.35-0.60 _ _ _ _ Balance

390 C17460 0.15-0.50 _ 1.0-1.4 _ _ _ Balance

Note: Copper plus additions equal 99.5% minimum.

Chemical Composition(weight percent)

Page 6: Guide to Copper Beryllium - · PDF fileBrush Wellman is the leading worldwide supplier of High Performance Copper Alloys, including Copper Beryllium. We provide manufacturing excellence

are available as mill hardened strip.

Alloy 390™ combines the best attributes of the twoseparate families of commercial copper beryllium alloys– the strength of the “high strength” Alloy 25 with theconductivity of “high conductivity” Alloys 3 and 174.In addition to the combination of high strength andconductivity, Alloy 390™ has excellent stress relaxationresistance at elevated temperatures. In applicationswhere durability is important, its excellent fatiguestrength extends product life and improves productquality. Alloy 390™ is available as prehardened strip.

Wrought copper beryllium is available from BrushWellman in a variety of product forms. The followingparagraphs define the products most commonly speci-fied by copper beryllium users.

Strip is flat-rolled product, other than flat wire, 0.188inch or less in thickness, and supplied in coil form.

Wire is a solid section other than strip, furnished incoils or on spools or reels. Wire may be furnishedstraightened and cut to length, in which case it is clas-sified as rod.

Flat wire is 0.188 inch or less in thickness and 1-1/4inch or less in width. This designation includes squarewire 0.188 inch or less in thickness. In all cases sur-faces are rolled or drawn without having been slit,sheared or sawed. Flat wire is furnished in straightlengths or on spools or reels.

Rod is a round, hexagonal or octagonal solid sectionfurnished in straight lengths. Rod is supplied in randomor specific lengths.

Bar is a solid rectangular or square section thicker than3/ 16 inch and up to and including 12 inches wide.Bar is an extruded product. If cut from plate it is calledrolled bar. Edges are either sharp, rounded, or havesome other simple shape.

Plate is flat-rolled product thicker than 0.188 inch andover 12 inches wide.

Tube is a seamless hollow product with round or othercross section. Tube is normally extruded or drawn, andis supplied in random or specific length.

Extruded shape is a solid section other than round,hexagonal, octagonal, or rectangular. Shapes are

Brush 60® and Brush Alloy 174 offer users theopportunity to upgrade component performance overbronzes and brasses, particularly where conductivityand stress relaxation resistance are design considerations.Both are supplied with a yield strength up to 125 ksi, superior to other copper alloys such as phosphorbronze, silicon bronze, aluminum brasses and thecopper-nickel-tin alloys. Furthermore, they offer up to fivefold better electrical conductivity than thosealloys, and exhibit better stress relaxation resistance.Brush 60® offers an excellent combination of elasticmodulus, strength, formability and conductivity. Both

5

Wrought Products

Brush Alloy

25, 10, 190, 290Form 3 165 M25 174, 60

Cold RolledStrip ✓ _ _ ✓Flat Wire ✓ _ _ _Rectangular Bar ✓ _ _ _Square Bar ✓ _ _ _Plate ✓ _ _ _

Cold DrawnRod ✓ ✓ ✓ _Bar ✓ ✓ ✓ _Tube ✓ _ _ _Wire ✓ _ ✓ _Shapes ✓ _ ✓ _

Hot WorkedRod ✓ ✓ _ _Bar ✓ ✓ _ _Plate ✓ ✓ _ _Tube ✓ ✓ _ _

Special ShapesTurned Rod ✓ ✓ _ _Billets ✓ ✓ _ _Forgings ✓ ✓ _ _Extrusions ✓ ✓ _ _

Standard Product Forms

190, 290390, 174

60

Page 7: Guide to Copper Beryllium - · PDF fileBrush Wellman is the leading worldwide supplier of High Performance Copper Alloys, including Copper Beryllium. We provide manufacturing excellence

Elastic Thermal Expansion Thermal MeltingBrush Density Modulus Coefficient Conductivity Temp.Alloy lb/cu.in. 106 psi in/in/°F, 70°F to 400°F Btu/(ft•hr•°F) °F

25, 190, 2900.302 19 9.7 x 10 -6 60 1600-1800M25

165 0.304 19 9.7 x 10 -6 60 1600-1800

3 0.319 20 9.8 x 10 -6 140 1900-1980

10 0.319 20 9.8 x 10 -6 115 1850-1930

60 0.318 20 9.8 x 10 -6 128 1880-1960

174 0.318 20 9.8 x 10 -6 135 1880-1960

390 0.318 20 9.8 x 10 -6 128 1880-1960

Note: Tabulated properties apply to age hardened products. Before age hardening the density is:0.298 lb/cu.in. for Alloys 25, M25 and 165; 0.316 lb/cu.in. for Alloys 3 and 10

Typical Physical Properties

Custom fabricated parts are supplied to customerdrawings as finished or semi-finished parts. Such products are fabricated from basic product forms (rod, extrusions, plate, etc.) by processes such as ring rolling, forging, welding and machining.

Physical PropertiesThe thermal expansion coefficient of copper berylli-

um is independent of alloy content over the tempera-ture range in which these alloys are used. The thermalexpansion of copper beryllium closely matches that ofsteels including the stainless grades. This insures thatcopper beryllium and steel are compatible in the sameassembly.

Specific heat of copper beryllium rises with tempera-ture. For Alloys 25, M25 and 165, it is 0.086 Btu/(lb•F)at room temperature, and 0.097 Btu/(lb•F) at 200 F.For Alloys 3, 10, 174, Brush 60® and 390™ it risesfrom 0.080 to 0.091 Btu/(lb•F) over the same temperature range.

Magnetic permeability is very close to unity, mean-ing that the alloys are nearly perfectly transparent toslowly varying magnetic fields.

Copper beryllium high strength alloys are less densethan conventional specialty coppers, often providingmore pieces per pound of input material. Copperberyllium also has an elastic modulus 10 to 20 percent higher than other specialty copper alloys.Strength, resilience, and elastic properties make copper beryllium the alloy of choice.

produced to the user’s specification and are suppliedin straight lengths.

Forgings, made from cast billet, are supplied in formsranging from simple geometric configurations to near-net shapes according to user specifications.

Copper beryllium’s physical and mechanical propertiesdiffer considerably from those of other copper alloysbecause of the nature and action of the alloying ele-ments, principally beryllium. Varying the berylliumcontent from about 0.15 to 2.0 weight percent pro-duces a variety of alloys with differing physical properties. Typical values of some of these propertiesare presented in the table on this page.

Whether a high strength or a high conductivityalloy, some physical properties remain similar. Forexample, the elastic modulus of the high strengthalloys is 19 million psi; for the high conductivityalloys, 20 million psi. Poisson’s ratio is 0.3 for all compositions and product forms.

A physical property that differs significantlybetween alloy families is thermal conductivity, whichranges from about 60 Btu/(ft•hr•F) for high strengthalloys to 140 Btu/(ft•hr•F) for the high conductivitygrades. The thermal and electrical conductivities ofcopper beryllium promote its use in applicationsrequiring heat dissipation and current carrying capaci-ty. Electrical conductivity is listed with mechanicalproperties in the Product Guide section of this book.

6

Alloy Guide

Page 8: Guide to Copper Beryllium - · PDF fileBrush Wellman is the leading worldwide supplier of High Performance Copper Alloys, including Copper Beryllium. We provide manufacturing excellence

ProductGuideStrip 8Wire 14Rod, Bar and Tube 16Plate and Rolled Bar 18Forgings and Extrusions 20Drill String Products 21Other Products and Services 22

7

Brush Wellman copper berylliumwrought products are recognized world-wide for unequalled quality and reliabilityamong high performance copper base alloys.The products are stocked in a wide range ofsizes and shapes. Moreover, because copperberyllium performs well in most metalworking andjoining processes, special configurations can be producedeconomically. Mechanical and electrical properties are presented in this section (English units are standard – metric equivalents are available on request). These proper-ties aid design by guiding size and temper selection but the tabulations do not limityour choice. A narrower range or a property outside the range are frequentlyrequested. We often produce to user specifications and we welcome the challenge ofa special product.

Page 9: Guide to Copper Beryllium - · PDF fileBrush Wellman is the leading worldwide supplier of High Performance Copper Alloys, including Copper Beryllium. We provide manufacturing excellence

StripBrush Wellman copper beryllium strip is used across abroad spectrum of applications. For example, a formedspring is often the active element in a signal or currentdirecting device. In a connector, a copper berylliumcontact regulates insertion force to encourage contactwiping action, provides a high normal force to mini-mize contact resistance, and maintains withdrawalforce to ensure conducting path integrity.

This accomplishment often requires an intricatestamped contact that combines flexing and stiffeningmembers in the same part. Among the many copperberyllium tempers described on this and followingpages, there is one with compliance and formability tomeet requirements of nearly any contact spring design.

Other benefits of copper beryllium strip include thefollowing:• In many tempers, strength and forming characteris-

tics do not vary with direction (isotropic). Deepdrawn bellows or disc diaphragms for pneumaticcontrols depend on nondirectional properties both inmanufacture and in service.

• Shielding strips that ground electromagnetic interfer-ence have demanding forming requirements, butalso require strength and endurance.

• Relay contacts and switch parts must resist the actionof repeatedly applied loads, sometimes at moderate-ly elevated temperature, and therefore must havehigh fatigue strength.

• High hardness is a benefit in insulation displacementconnectors that must cut through conductor wireinsulation to make reliable contact.

Thickness is critical in spring design, strongly influ-encing force-deflection characteristics. For this reasonBrush Wellman guarantees strip thickness to be uni-form within tolerance limits shown in the adjoiningtable. Width of the slit strip is held to ±0.003 inch inall widths up to 3.5 inches.

Strip curvature, either edgewise (camber), or in theplane of the strip (coilset or crossbow) also is carefullycontrolled. In press working, excellent strip shape aidsproper feed, particularly with progressive dies.

8

Product Guide

Brush UNSAlloy Number Strip

ASTM B 194QQ-C-533

25 C17200 AMS 4530, 4532SAE J 461, 463

190 C17200 ASTM B 194

290 C17200 ASTM B 194

ASTM B 5343 C17510 MIL-C-81021

RWMA Class 3

174 C17410 ASTM B 768

Brush 60® C17460 ASTM B 768

Specifications

Tolerance(inches)

ASTM American Society for Testing and MaterialsQQ Federal SpecificationMIL Military SpecificationSAE Society of Automotive EngineersAMS Aerospace materials Specification

(Published by SAE)RWMA Resistance Welder Manufacturer’s

AssociationNote: Unless otherwise specified, material will

be produced to ASTM specification.

Strip Brush WellmanThickness Standard Tolerance

over incl. (plus or minus)0.0020 - 0.0040 0.000150.0040 - 0.0060 0.000200.0060 - 0.0090 0.00025

0.0090 - 0.0130 0.000300.0130 - 0.0260 0.000400.0260 - 0.0370 0.00060

0.0370 - 0.0500 0.000800.0500 - 0.0750 0.0010

Note: Tolerances apply to rolled and mill hardened strip.

Page 10: Guide to Copper Beryllium - · PDF fileBrush Wellman is the leading worldwide supplier of High Performance Copper Alloys, including Copper Beryllium. We provide manufacturing excellence

Temper DesignationsCopper beryllium properties are determined in part bycomposition, but cold work and age hardening arealso important. The combined effect of non-composi-tional factors is defined in the alloy’s “temper.” Whenalloy number and temper are specified on a drawing or order, for example Brush Alloy 3 AT, the user isassured of a specific set of properties.

Temper designations are defined in the specificationASTM B 601, “Standard Practice for TemperDesignations for Copper and Copper Alloys.” Less precise terms such as “quarter hard” and “half hard”are also recognized by suppliers and users. The relationship between these terms and the ASTMnomenclature is given in the table on this page.

Copper beryllium in the solution annealed conditionis designated by a suffix letter “ A “ , for example Alloy25 A. This is the softest condition in which the alloycan be obtained. Suffix letter “H” denotes an alloy thathas been hardened by cold working, such as by rollingor drawing, for example Alloy 25 H. The suffix letter

“T” following an “A” or “H” designates an alloy whichhas been given a standard heat treatment, and as aresult has “peak” properties, for example Alloy 25 HT.

Copper beryllium bearing an “M” suffix has receivedproprietary mill processing, for example Alloy 190HM, and guarantees properties within a specific range.

Alloy 3 is available in the fully aged condition. Theproducts are designated AT for annealed and precipita-tion treated; and HT for annealed, cold rolled, and precipitation treated. Brush 60® and Alloy 174 are provided only in the cold rolled, precipitation treatedcondition.

9

Temper Designations

Brush ASTM Cold Rolled ThicknessDesignation Designation Description Reduction in Percent

A TB00 Solution Annealed 01/4 H TD01 Quarter Hard 111/2 H TD02 Half Hard 213/4 H TD03 Three-Quarter Hard 29

H TD04 Hard 37

AT TF001/4 HT TH01 The suffix “T” added to temper designations1/2 HT TH02 indicates that the material has been age3/4 HT TH03 hardened by the standard heat treatment.

HT TH04

AM TM001/4 HM TM011/2 HM TM02 Mill hardened to specific property ranges,

HM TM04 no further heat treatment is required.SHM TM05XHM TM06

XHMS TM08

HTR _Mill hardened to provide properties not

HTC _available by standard age hardening.Alloy 3 only.

Page 11: Guide to Copper Beryllium - · PDF fileBrush Wellman is the leading worldwide supplier of High Performance Copper Alloys, including Copper Beryllium. We provide manufacturing excellence

10

Product Guide - StripM

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Page 12: Guide to Copper Beryllium - · PDF fileBrush Wellman is the leading worldwide supplier of High Performance Copper Alloys, including Copper Beryllium. We provide manufacturing excellence

11

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ee n

ote

4)Te

nsile

Elon

gati

onR

ockw

ell

Tem

per

Stre

ngth

Perc

ent

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mon

d(n

ote

2)(k

si)

(not

e 3)

Pyra

mid

B o

r C

Supe

rfic

ial

TM00

100

min

75-9

519

-35

40-4

522

5-30

9B

98-C

3130

T81-

30N

5217

-26

TM02

120

min

95-1

1514

-30

42-4

825

5-33

9C

25-3

430

N46

-54

17-2

6

TM04

140

min

115-

135

9-25

44-5

028

5-36

9C

28-3

830

N48

-58

17-2

6

TM06

155

min

135-

155

6-13

47-5

731

7-39

3C

32-4

030

N52

-60

17-2

6

TM08

175

min

155-

175

3-15

50-6

034

5-42

9C

35-4

330

N55

-62

17-2

6

3/4

HT

(TH

03)

115-

135

95-1

1511

min

46-4

7_

__

50 m

in

HT

(TH

04)

120-

140

105-

125

10 m

in42

-45

__

_50

min

1/2

HT

(TH

02)

95-1

1580

-100

10-2

040

-45

180-

230

B89

-98

30T7

5-82

50 m

in

HT

(TH

04)

110-

130

100-

120

7-17

40-4

521

0-27

8B

95-1

0230

T79-

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(TF0

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0-13

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538

-44

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275

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-100

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7-82

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0

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(TH

04)

110-

135

95-1

208-

2042

-47

216-

287

B95

-102

30T7

9-83

48-6

0

HT

(TH

04)

135-

153

138-

158

1 m

in.

35-4

0_

__

44 m

in.

Page 13: Guide to Copper Beryllium - · PDF fileBrush Wellman is the leading worldwide supplier of High Performance Copper Alloys, including Copper Beryllium. We provide manufacturing excellence

Annealed strip has excellent formability with bothlongitudinal and transverse bends posing no formingproblems. Certain mill hardened tempers also havelow directionality. Because of this isotropy, specialconsideration does not have to be given to the manner in which parts are stamped relative to the rolling direction. In many instances

FormingThe accompanying table is a guide to temper selectionbased on forming requirements. The R/t ratios in thetable indicate the allowable punch radius (R) for a 90degree bend as a function of strip thickness (t). Low R/timplies high formability.

12

Product Guide - Strip

FormabilityAlloy R/t Ratio Alloy and R/T Ratio

and Heat- for 90° Bend Mill for 90° BendFormability Specific treatable Direction of Bend Hardened Director of Bend

Rating Formability Temper L T Temper L T

Used for deepdrawn and 25A 0 0severely cuppedor formed parts

ExcellentAs formable asthe annealed 25 1/4H 0 0 290 TM00 0 0temper buteasier to blank 290 TM02 0 0

190 AM 0 0Used for 174 1/2 HT 0.5 0.5

Very Good moderately 25 1/2H 0.5 1.0 190 1/4 HM 0.5 0.5drawn or cupped 60 3/4 HT 0.7 0.7parts. 3 AT 1.0 1.0

290 TM04 1.0 1.0

Formable to a 190 1/2 HM 0.5 1.090° bend around 60 HT 1.5 1.5

Good a radius less 25H 1.0 2.9 390HT(<0.004") 2.0 2.0than 3 times the 3 HT 2.0 2.0stock thickness 190 HM 2.0 2.0

290 TM06 2.5 2.0

174 HT 1.2 5.0Suitable for light 190 SHM 2.8 3.2

Moderate drawing; used 290 TM08 3.5 3.0for springs. 390HT(>0.004") 3.5 3.5

190 XHM 4.0 5.0

For essentiallyflat parts;

Limited forming requires 190 XHMS 5.0 10.0very generouspunch radius

Note: Formability ratios are valid for strip up to 0.050inch thick. Strip less than 0.010 inch thick will formsomewhat better than shown. Values reflect thesmallest punch radius that forms a strip sample into a90° “vee”-shaped die without failure.

R = punch radius t = stock thickness

Suitable for lightdrawing; used

for springsModerate

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Alloys 3, 174,390™, Brush 60®

this will permit nesting of parts to allow efficient mate-rial utilization.

The tooling requirements for stamping and drawingcopper beryllium are the same as those required forany copper base alloy with similar hardness. Toolsshould be kept sharp, with punch to die clearances ofabout 5% of the stock thickness (or 2-1/2% per side).This practice will minimize edge burr formation duringblanking or shearing. Burrs should be removed prior toage hardening since they can be the source of fatiguefailure in highly stressed parts. Draft angles should beabout 1/2 degree per side greater than those used forphosphor bronze or brass to preclude copper berylliumbuildup on the punches, which could change dieclearances. Lubricants can prolong die life, but thosecontaining sulfur may cause staining and a possibleembrittlement of copper beryllium.

Springback becomes more pronounced as temperand strength increase. Springback can be controlled byoverforming bends to achieve required angles. For agiven punch radius, springback decreases with increas-ing strip thickness.

Stress Relaxation Resistance Copper beryllium alloys are often chosen because oftheir inherent resistance to stress relaxation.Miniaturization in computer hardware, automotiveinterconnections and aerospace systems has accentedthe importance of high thermal stability. Today, manyelectronic contacts and other spring elements mustremain stable longer while operating at higher temper-atures than ever before.

Stress relaxation is commonly evaluated on samplescut from strip and subjected to constant elastic bend-ing strain at moderately elevated temperature. In onecommon method, a sample is secured in a fixture anddeflected as a cantilever beam to an initial stress that isa predetermined fraction of the alloy’s 0.2 percentyield strength, typically 75 percent. The fixture anddeflected sample are exposed to high temperature forextended time, usually up to 1,000 hours. Stress relax-ation causes permanent set. The ratio of permanent setto initial deflection defines the degree of loss of initialbending stress caused by relaxation.

The stress relaxation behavior of several alloys is dis-played in the figures on this page. In these figures, thepercentage of bending stress remaining after exposureis related to temperature and time by a Larson-Millertechnique. This method allows extrapolation over arange of time and temperature.

13

Stress Relaxation Resistance

1. Select the accumulated exposure timealong the right hand axis.

2. Extend a horizontal line from this point tothe exposure temperature line (thediagonal lines that are identified at top).

3. Draw a vertical line from the time-temperature intersection point to thestress relaxation curve.

4. Draw a horizontal line from this inter-section to the remaining stress axis todetermine the percentage of stressremaining after exposure.

13

Alloy25

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14

Product Guide - Strip

Wire that is straightened and cut to length is called rod.

Wire is available with cross sections other thanround. “Shaped” wire plays an important role in specialized applications. For example, flat wire is usedin retractable antennas and telecommunication cables.Flat wire can also be used in place of narrow slit strip.Although there is a width to thickness ratio abovewhich flat wire is impractical, many times a savings isrealized. Flat wire eliminates a slitting burr.

Square wire is used in electronic contacts especiallywhere wire wrapping requires sharp corners for reliable contact. Occasionally square or rectangularwire requires a beveled corner for orientation. Theseand other less common shape requirements can bemet with copper beryllium wire.

Brush Wellman supplies wire in diameters from0.500 inch down to 0.050 inch with tolerances shownin the table on this page. Finer wire can be suppliedeither by special order from Brush Wellman or fromanyone of a number of copper beryllium wire redrawers.

Wire is supplied annealed (A), or in quarter hard(1/4H), half hard (1/2H), or full hard (H) tempers. Inspecial cases however, prehardened (also called“pretempered”) wire is available. This product offersversatility in strength and durability for products withmild to somewhat stringent forming requirements.

Wire is one of the most versatile copper berylliumproduct forms with no other product having applica-tions based on as many diverse attributes.Applications of round wire include:

• Miniature machined electronic sockets

• Long travel coil springs

• Cold headed fasteners

• Spring loaded test probes

• Lightweight, fatigue resistant stranded cable

• Bandoliered connector contacts

• Braided shielding cloth

• Corrosion and biofouling resistant marine wire andwire mesh structures

• Eyeglass frames

Wire

Tolerance(inches)

Specifications

Brush UNSAlloy Number Wire

ASTM B 197QQ-C-530

25 C17200 AMS 4725SAE J 461, 463

ASTM B 197M25 C17300 QQ-C-530

3 C17510 *

10 C17500 *

ASTM American Society for Testing and MaterialsQQ Federal SpecificationSAE Society of Automotive EngineersAMS Aerospace Materials Specification

(Published by SAE)Note: Unless otherwise specified, material will

be produced to ASTM specification.*Product available, specifications being prepared

Brush WellmanStandard Tolerance

(plus or minus)Wire Diameter Coldover incl. Drawn Annealed

0.0500 - 0.0800 0.0003 0.0010.0800 - 0.1250 0.0004 0.0020.1250 - 0.2500 0.0006 0.002

0.2500 - 0.3125 0.0007 0.0020.3125 - 0.4060 0.0010 0.0020.4060 - 0.500 0.0010 0.002

Note: Out of Round tolerance is half the diameter tolerance.

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15

Mechanical and Electrical Properties of Copper Beryllium Wire

Yield ElectricalTemper Heat Wire Tensile Strength Elongation Conductivity

Alloy(*) Treatment Diameter Strength 0.2% offset percent percent

inch ksi ksi IACS

A _ 0.050-0.500 58-78 20-30 30-60 15-19(TB00)

1/4 H _ 0.050-0.500 90-115 75-105 3-25 15-19(TD01)

1/2 H _ 0.050-0.500 110-135 90-125 2-15 15-19(TD02)

3/4 H _ 0.050-0.080 130-155 115-150 2-8 15-19(TD03)

H _ 0.050-0.080 140-165 130-160 1-6 15-19(TD04)

AT3 hr 600-625F 0.050-0.500 160-200 145-180 3 min 22-28

(TF00)

1/4 HT2 hr 600-625F 0.050-0.500 175-210 165-200 2 min 22-28

(TH01)

1/2 HT1-1/2hr 600-625F 0.050-0.500 185-215 170-210 2 min 22-28

(TH02)

3/4 HT1 hr 600-625F 0.050-0.080 190-230 175-220 2 min 22-28

(TH03)

HT1 hr 600-625F 0.050-0.080 195-230 180-220 1 min 22-28

(TH04)

A _ 0.050-0.500 35-55 10-30 20-60 20-30(TB00)

H _ 0.050-0.500 65-80 55-75 2-20 20-30(TD04)

AT3 hr 900-925F 0.050-0.500 100-130 80-110 10 min 45-60

(TF00)

HT2 hr 900-925F 0.050-0.500 110-140 95-125 10 min 48-60

(TH04)

*ASTM alphanumeric code for product tempers.

25C17200

andM25

C17300

3C17510

and10

C17500

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16

Product Guide

Applications include:• Antigalling wear plates• Guide rails and bus bars• Machined threaded fasteners• Die inserts for resistance welding

Tube comes in a wide range of diameter/wall thicknesscombinations. These range from the ultra thin wallconfigurations produced by tube redrawing specialists,to light wall cold drawn tube, to heavy wall hotworked product. Typical applications are:• High deflection, strong instrument tubes such as

bourdon and pitot types (redrawn tube)• Bearings for aircraft landing gear and pivoting

members• Long life tri-cone drilling bit bushings• Pressure housings for precision magnetometers

and other instrumentsAn important use of rod, bar and tube is in products

for resistance welding applications. Copper berylliumfills the needs of this industry by providing hardnessand electrical conductivity for precision in structuralcomponents and durability in electrodes. Ease of fabri-cation in bending and machining also contributes tocost effective resistance welding.

Rod, bar and tube are available in the hardened condition. Annealed and precipitation hardened (AT), and annealed, cold drawn and precipitationhardened (HT) tempers are available as shown in thetable on page 17.

Rod, Bar and TubeLengths from one inch to thirty feet; sections from 3/8inch to more than 9 inches; precision and versatilityfrom cold drawing and extrusion; simplicity of agehardening; strength, corrosion resistance, machinabili-ty...these are just a few of the useful features that makerod, bar, and tube unique.

Rod is supplied in straight lengths for machining orforming into finished components by the user. Formingis done before age hardening, machining usually afterhardening. Typical applications include:• Low maintenance bearings and bushings• Rugged resistance welding gun structural

components• Core pins and other inserts for plastic injection

molding and metal die casting

Bar also is produced in straight lengths, but has a crosssection other than round. Square, rectangular andhexagonal are, the most common.

Specifications

Tolerance(inches)

Brush UNS Rod, BarAlloy Number and Tube

ASTM B 196, 251, 643QQ-C-530MIL-C-21657

25 C17200 SAE J 461, 463AMS 4533, 4534, 4535,AMS 4650, 4651RWMA Class 4

ASTM B 196M25 C17300 QQ-C-530

MIL-C-21657

ASTM B 196165 C17000 SAE J 461, 463

RWMA Class 4

ASTM B 441, 9373 C17510 SAE J 461, 463

RWMA Class 3

ASTM B 441, 93710 C17500 SAE J 461, 463

RWMA Class 3

ASTM American Society for Testing and MaterialsQQ Federal SpecificationMIL Military SpecificationSAE Society of Automotive EngineersAMS Aerospace Materials Specification

(Published by SAE)RWMA Resistance Welder Manufacturer’s

AssociationNote: Unless otherwise specified, material will

be produced to ASTM specification.

Brush WellmanDimension Standard Tolerance

Product over incl. plus or minus

Cold Drawn 0.375 0.500 0.002Round Rod 0.500 1.00 0.003(diameter) 1.00 2.00 0.004

2.00 3.00 0.2% of sizeCold Drawn 0.150 0.500 0.004Hex Rod 0.500 1.00 0.005(diameter) 1.00 2.00 0.006

2.00 3.00 0.4% of sizeAs extruded 0.750 1.25 0.020Round Rod 1.25 2.50 0.030(diameter) 2.50 6.00 0.060

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17

Mechanical and Electrical Properties of Copper Beryllium Rod, Bar and Tube

OutsideDiameter

or Distance Yield Hardness ElectricalBetween Tensile Strength Rockwell Conductivity

Temper Heat Parallel Surfaces Strength 0.2% offset Elongation B or C percentAlloy ( * ) Treatment inch ksi ksi percent Scale IACS

A all 60-85 20-35 20-60 B45-85 15-19(TB00) sizes

up to ³⁄₈ 90-130 75-105 8-30 B88-103 15-19

over ³⁄₈ to 1 90-125 75-105 8-30 B88-102 15-19

over 1 to 3 85-120 75-105 8-20 B88-101 15-19

up to 3 165-200 145-175 4-10 C36-42 22-28

over 3 165-200 130-175 3-10 C36-42 22-28

up to ³⁄₈ 185-225 160-200 2-9 C39-45 22-28

over ³⁄₈ to 1 180-220 155-195 2-9 C38-44 22-28

over 1 to 3 175-215 145-190 4-9 C37-44 22-28

A all 60-85 20-35 20-60 B45-85 15-19(TB00) sizes

up to ³⁄₈ 90-130 75-105 8-30 B92-103 15-19

over ³⁄₈ to 1 90-125 75-105 8-30 B91-102 15-19

over 1 to 3 85-120 75-105 8-20 B88-101 15-19

up to 3 150-190 125-155 4-10 C32-39 22-28

over 3 150-190 125-155 3-10 C32-39 22-28

up to ³⁄₈ 170-210 145-185 2-5 C35-41 22-28

over ³⁄₈ to 1 170-210 145-185 2-5 C35-41 22-28

over 1 to 3 165-200 135-175 4-9 C34-39 22-28

A all35-55 10-30 20-35 B20-50 20-30(TB00) sizes

Hup to 3 65-80 50-75 10-15 B60-80 20-30(TD04)

AT3 hr 900°F

all100-130 80-100 10-25 B92-100 45-60(TF00) sizes

HT2 hr 900°F up to 3 110-140 95-125 5-25 B95-102 48-60(TH04)

H(TD04)

AT(TF00)

3 hr600°F-625°F

2-3 hr600°F-625°F

2-3 hr600°F-625°F

HT(TH04)

H(TD04)

AT(TF00)

HT(TH04)

3 hr600°F-625°F

25C17200

andM25

C17300

165C17000

3C17510

and10

C17500

*ASTM alphanumeric code for product tempers.

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18

Product Guide

ed alloys are selected when heavier cuts using morerigid tooling can be made.

If the “A” or “H” temper is selected, parts are usuallymachined oversize to accommodate the slight dimen-sional change that occurs during hardening. The partsare then finish machined.

These flat rolled products are noted for dimensionalstability both in precision machining and in service.Thermal management devices of various types arecommon applications. Thermal conductivity, fatigueresistance, and excellent machinability are key featurescontributing to cost effective use.Examples of plate and rolled bar applications are:

• Heat tolerant molds for plastic injection systems

• Structural components in electrical resistance welding

• Galling resistant wear plates and rub strips

• Metal die casting, plastic blow molding, and injection molding inserts

• Water cooled chill plates for computer memorydevices

• Damage resistance, nonsparking tools

Plate and rolled bar are made with exacting attentionto detail. Plate is a straight length of flat rolled productthicker than 0.188 inches and wider than 12 inches.Rolled bar is a rectangular or square section that isabrasively cut or sawed from plate.

Solution annealed (A), cold rolled (H), and age hardened tempers (AT and HT) are available. Temperselection depends on the application and the methodof component fabrication. For example, with Alloy 25the annealed temper is the preferred selection whensmall holes are to be drilled; age hardening to thedesired hardness is performed after drilling. Heat treat-

Plate and Rolled Bar

Tolerance(inches)

Specifications

Brush WellmanThickness Standard Tolerance

over incl. plus minus0.188 - 0.205 0.010 00.205 - 0.300 0.012 00.300 - 0.500 0.015 00.500 - 0.750 0.019 00.750 - 1.00 0.023 01.00 - 1.50 0.028 01.50 - 3.0 0.033 0

Note: Tolerances are for widths up to 24 inches. Specificwidth tolerance is plus or minus 1/16 inch.

Brush UNS Plate andAlloy Number Rolled Bar

ASTM B 194QQ-C-530SAE J 461, 463

25 C17200 AMS 4530, 4533, 4534AMS 4650, 4651RWMA Class 4

ASTM B 534165 C17000 SAE J 461, 463

RWMA Class 4

ASTM B 5343 C17510 SAE J 461, 463

RWMA Class 3

ASTM B 53410 C17500 SAE J 461, 463

RWMA Class 3

ASTM American Society for Testing and MaterialsQQ Federal SpecificationMIL Military SpecificationSAE Society of Automotive EngineersAMS Aerospace Materials Specification

(Published by SAE)RWMA Resistance Welder Manufacturer’s

AssociationNote: Unless otherwise specified, material will

be produced to ASTM specification.

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19

Mechanical and Electrical Properties of Copper Beryllium Plate and Rolled Bar

Yield Hardness ElectricalTensile Strength Rockwell Conductivity

Temper Heat Thickness Strength 0.2% offset Elongation B or C percentAlloy ( * ) Treatment inch ksi ksi percent Scale IACS

A all 60-85 20-35 20-60 B45-85 15-19(TB00) sizes

up to ³⁄₈ 90-130 75-105 8-20 B91-103 15-19

over ³⁄₈ to 1 90-125 75-105 8-20 B90-102 15-19

over 1 to 2 85-120 75-105 8-20 B88-102 15-19

over 2 to 3 85-120 75-105 8-20 B88-102 15-19

AT all 165-200 140-175 3-10 C36-41 22-28(TF00) sizes

up to ³⁄₈ 180-215 160-200 1-5 C38-45 22-28

over ³⁄₈ to 1 180-220 155-200 1-5 C38-44 22-28

over 1 to 2 175-215 150-200 2-5 C37-43 22-28

over 2 to 3 165-200 130-180 2-5 C36-42 22-28

A all 60-85 20-35 20-60 B45-85 15-19(TB00) sizes

up to ³⁄₈ 90-130 75-105 8-20 B92-103 15-19

over ³⁄₈ to 1 90-125 75-105 8-20 B91-102 15-19

over 1 to 2 85-120 75-105 8-20 B88-101 15-19

over 2 to 3 85-120 75-105 8-20 B88-101 15-19

all150-190 130-155 3-10 C33-39 22-28sizes

up to ³⁄₈ 170-210 135-165 2-5 C35-41 22-28

over ³⁄₈ to 1 170-210 135-165 2-5 C35-41 22-28

over 1 to 2 165-200 135-165 2-5 C34-39 22-28

over 2 to 3 160-190 125-165 2-5 C34-38 22-28

A all35-55 25-45 20-35 B20-45 20-30(TB00) sizes

Hup to 3 70-85 55-80 2-8 B78-88 20-30(TD04)

AT3 hr 900°F

all100-130 80-100 8-20 B92-100 45-60(TF00) sizes

HT2 hr 900°F up to 3 110-140 100-120 5-15 B95-102 48-60(TH04)

H(TD04)

3 hr 625°F

2 hr 625°F

3 hr 625°F

2 hr 625°F

HT(TH04)

H(TD04)

AT(TF00)

HT(TH04)

25C17200

165C17000

3C17510

and10

C17500

*ASTM alphanumeric code for product tempers.

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20

Product Guide - Strip

• Corrosion resistant, antigalling cylinders for under-sea cable communication system repeater housings

Forgings and ExtrusionsThe ease with which copper beryllium can be workedallows fabrication of large, near-net shape componentsby forging and extrusion.

Forging extends the size range available in copperberyllium components. Processes include rotary forging, ring rolling, roll forging, swaging, cold heading, and various open and closed die techniques.Forgings include:• Disc shaped resistance seam welding electrodes

(open die forging)• Generator rings (ring forged)• Aerospace and hydrospace components

• Gears and power transmission couplings

Extrusions find application in continuous long lengths,where economy is achieved by near-net shape techniques; in short lengths where near-net shape processing is combined with high production rate; andin back extruded parts where relatively large diameterhollows can be produced economically. Extrusionsinclude:

• Wear resistant guide rails for computer peripheralequipment

• Heat and fatigue resistant mold segments for continuous casting equipment

• Abrasion and galling resistant dies and die inserts for resistance flash welding

Specifications

Mechanical and Electrical Propertiesof Copper Beryllium Forgings and Extrusions

Brush UNS ForgingsAlloy Number and Extrusions

ASTM B 570QQ-C-530

25 C17200 SAE J 461, 463AMS 4650RWMA Class 4

ASTM B 570165 C17000 SAE J 461, 463

RWMA Class 4

3 C17510 RWMA Class 3

SAE J 461, 46310 C17500 RWMA Class 3

ASTM American Society for Testing and MaterialsQQ Federal SpecificationSAE Society of Automotive EngineersAMS Aerospace Materials Specification

(Published by SAE)RWMA Resistance Welder Manufacturer’s

AssociationNote: Unless otherwise specified, material will

be produced to ASTM specification.

Yield Hardness ElectricalTemper Heat Tensile Strength Elongation Rockwell Conductivity

Alloy (*) Treatment Strength 0.2% offset percent B or C percentksi ksi Scale IACS

A60-85 20-40 35-60 B45-85 15-19(TB00)

AT3 hr 625°F 165-200 130-175 3-10 C36-42 22-28(TF00)

A60-85 20-40 35-60 B45-85 15-19(TB00)

AT3 hr 650°F 150-190 120-155 3-10 C32-39 22-28(TF00)

A35-55 20-40 20-35 B20-50 20-35(TB00)

AT3 hr 900°F 100-120 80-100 10-25 B92-100 45-60(TF00)

25C17200

165C17000

3C17510

and10

C17500

*ASTM alphanumeric code for product tempers.

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21

Drill String ProductsA special temper of copper beryllium has been developed to meet the specific needs of oil and gaswell drilling. Components for this demanding environ-ment serve as part of the drill string’s bottomholeassembly and enclose sensitive magnetic measuringinstrumentation. These tubular components must betransparent to magnetic fields, must resist corrosion,must be strong enough to withstand the stress of tightly torqued threaded connections, and toughenough to withstand the rotating and bending abuse of downhole service.

A copper beryllium grade called Brush Alloy 25Drill String Temper meets these requirements. In addi-tion, it is noted for its ability to minimize galling in threaded tool joints. The “thread saver sub”, for example, eliminates galled threads in the drill string bottomhole assembly and prolongs the life of adjoining components.

Drill String Temper is not susceptible to chloridestress corrosion cracking as the table on this pageshows. It resists carbon dioxide and it is effectivelyimmune to hydrogen embrittlement. In sour environ-ments it is used for drilling and well logging whereexposure is intermittent and inhibitors are used.

Brush Alloy 25 has low magnetic permeability(between 0.997 and 1.003) that does not change undersevere service or handling, is easily machined, andresists thread damage without the need for specialcoatings or treatments.

Brush Alloy 25 meets all requirements of AmericanPetroleum Institute Spec 7 for drill collars and rotarysubstitutes. Mechanical properties and results of per-formance tests are in the accompanying tables.Examples of drill string applications are:• Nonmagnetic drill collars• Measurement while drilling components• Instrument housings• Threaded saver subs• Drill rod for coring tools in mining or hydrocarbon

drilling and exploration• Mud motor flexible drive shafts• Cross over subs

Resistance toChloride Stress Corrosion Cracking

Resistance to Gallingin Threaded Joint

Mechanical Properties forCopper Beryllium Drill String Subs

and Collars

Temperature°F 300 311 300

Applied stress(percent of 0.2%yield strength) 100 100 100

Oxygen content(parts per millionin saturating gas) 1* 1 5000*

pH 8 3 7

Chloride concentration(weight percent)

sodium 3 0 0potassium 10 0 6magnesium 0 42 25

Test duration, hours 720 1000 1000

Test result no no nocracking cracking cracking

*Total pressure 1000 psi

MinimumMinimum Yield

Drill Collar Tensile Strength MinimumOutside Dia. Strength 0.2% offset Elongation

inches ksi ksi percent

up to 7 140 110 12

7 - 11 135 100 13

over 11 120 190 13

Note: Tensile tests per ASTM E 8Yield strength by 0.2% offset method.

Onset of Galling FailureCouple (percent of API Minimum Torque)

(pin/box) Lubricated Nonlubricated

Stainless/Stainless1 130 < 100Alloy25/Stainless2 NF at 180 –Alloy25/Stainless1 NF at 200 200Alloy25/AISI 41402 NF at 205 –Alloy25/Alloy251 NF at 200 NF at 200

1API NC-38 NF – No Failure2API 6-5/8 REG

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Product Guide - Strip

Manufacturing ServicesFor copper beryllium requirements beyond thosedescribed in the Product Guide, our manufacturingfacilities and service centers are prepared to meet yourspecial needs. Examples include the following:• Traverse winding• Tension leveling of cold rolled strip• Near net shape sawing of billet, plate and rod• Shearing no specific length• Tin or solder coating

Custom FabricationCustom Fabrication offers the user an alternative toinhouse fabrication of copper beryllium parts. BrushWellman’s manufacturing capability often provides aneconomical route to a custom input blank for theuser’s finish machining process. An experienced BrushWellman team, after completing a producibility analy-sis of the customer’s drawings and specifications canoffer guidelines to producing a quality product costeffectively and on time.

Certified SuppliersIn response to a need beyond internal capabilities,Brush Wellman can refer the user to a supplier withdemonstrated expertise in manufacturing copper beryllium products with specialized equipment andtechnology. Examples include the following:• Fine wire drawing• Thin foil rolling• Thin wall tube redrawing• Multigage strip contouring• Prototype blanking and forming• Photochemical machining• Fixture age hardening• Joining• Inlay cladding• Solder striping• Electron beam welding• Zone annealing• Electroplating

Contact a Brush representative to explore opportunities.

Other Products and ServicesIn addition to the copper beryllium products detailedin this book, Brush Wellman offers a full line of castand wrought products and a range of special customer services. A few are described on this page, but thenumber far exceeds those listed. Brush is always willing to work with users to find a product or servicethat makes an application succeed.

Master AlloysCommon master alloys include 4% beryllium copper,5% beryllium aluminum, and 6% beryllium nickel.Supplied as ingot or shot, master alloy is a melt addi-tive used for one or more of the following purposes: todeoxidize or desulfurize copper and nickel; to hardencopper, nickel, and aluminum; to improve cleanliness,fluidity, and corrosion resistance in aluminum; to mini-mize loss of oxidizable elements such as magnesiumin aluminum; to protect against oxidation and meltignition in magnesium; and to control composition inproduction of commercial beryllium-containing alloysin many base metal systems.

Casting IngotCopper beryllium casting ingot is available in highconductivity and high strength compositions for castingwithout additions. Investment, shell, permanent mold,sand, centrifugal and pressure casting are a few of themethods used. Beryllium in copper increases melt fluidity and cleanliness while providing a heat treat-able casting. Replication of mold detail in cast parts is excellent.

moldMAX® and PROtherm®

moldMAX® and PROtherm® are available in a selectionof plate thickness and rod diameters. These heat treat-ed materials are used as mold components in the man-ufacture of plastic parts.

Nickel Beryllium For applications requiring high strength for service attemperatures up to 700 F, Brush Wellman producesnickel beryllium Alloy 360. The fully aged alloy iscapable of tensile strength approaching 300 ksi.

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EngineeringGuideHeat Treating Fundamentals 24Cleaning and Finishing 30Soldering, Brazing, and Welding 31Machining 32Hardness 33Fatigue Strength 35Corrosion Resistance 36Other Attributes 37

Topics related to designing and working with copper beryllium are highlighted in thissection. The emphasis is on alloy and product performance in fabrication and service environments. When more detail is needed, information is available in separate Brush Wellman publications.

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Engineering Guide

in describing alloy behavior.At concentrations of 1.6 to 2.0 weight percent

beryllium, a beryllium rich constituent known asgamma phase is present below 1100 F. This phaseforms as a result of the limited solid solubility of beryl-lium. In these alloys it is the primary contributor to precipitation hardening.

The binary diagram shows that heating above 1300 Fcauses beryllium to dissolve in the alpha solid solutionphase. A rapid quench to room temperature maintainsberyllium in solid solution. This process, called solu-tion annealing, makes the alloy soft and ductile, helpsregulate grain size, and prepares the alloy for age hardening. Since it is performed as part of the manufacturing process, most users do not anneal copper beryllium.

Heat Treating Fundamentals An awareness of the ways that composition, coldwork, and thermal processes interact to synthesizeproperties and microstructure is useful in designingand working with copper beryllium. Small berylliumadditions to copper, activated by mechanical and ther-mal processing, result in strength exceeding that ofmost copper base alloys and many hardened steels.Furthermore, controlled mechanical working and spe-cific thermal processing allow properties to be tailoredto meet a broad range of requirements. These funda-mental effects are explored on the following pages.

Phase DiagramsA binary equilibrium phase diagram approximating thebehavior of high strength alloys is shown below. Sincethese alloys contain up to 0.6 weight percent totalcobalt and nickel in addition to beryllium, the binaryphase diagram is not rigorously appropriate but it helps

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Heating the supersaturated solid solution to 600 Fand holding for 2 to 3 hours causes precipitation of thestrengthening phase and hardens the alloy.

The binary phase diagram shows that at 1590 F thesolubility limit is 2.7 percent (the cobalt additionreduces this to about 2.3). At room temperature, lessthan 0.25 percent beryllium is soluble. This differencein solubility is the driving force for hardening; fewother copper alloys compare. There are three reasonsfor adding cobalt to high strength alloys. First, andmost important, this addition promotes fine grain sizeby limiting grain growth during solution annealing.Second, cobalt makes precipitation hardening less timesensitive. Third, it increases maximum strength slightly.

A pseudobinary phase diagram (nickel beryllide incopper) for Alloy 3, a typical high conductivity alloy, is shown at the right on page 24. Altogether, the highconductivity alloys span the range from 0.15 to 0.7weight percent beryllium. However, in these alloysmost of the beryllium is partitioned to beryllide inter-metallics. Coarse beryllides formed during solidifica-tion limit grain growth during annealing, while fineberyllides formed during precipitation hardeningimpart strength.

The temperature ranges for solution annealing, andfor age hardening are higher for these alloys than forthe high strength alloys. The stability of the strengthen-ing phase at elevated temperature results in high resist-ance to creep and stress relaxation in this alloy family.

Cold Work ResponseCold work in an age hardening alloy denotes plasticdeformation at a temperature below the onset of pre-cipitation. A metalworking process changes the dimen-sions of a workpiece, typically in two directions, withrolling, drawing, bending, and upsetting being primeexamples of cold working operations. In contrast to hotworking, cold work elongates grains in the workingdirection, and deformation effects accumulate.

Cold work increases strength and hardness of cop-per beryllium as shown in the figures on this page. Areduction in ductility, measured by elongation, accom-panies this increase in strength.

The strengthening effects of cold work are especiallyimportant in age hardened products (see figures). Coldwork increases the number of precipitation sites andthereby accelerates age hardening. However, elonga-tion declines as cold work increases, but at a muchlower rate than in the unaged product.

25

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Engineering Guide

During processing of mill products, cold workingproduces excellent dimensional precision and shape.Annealing of cold worked copper beryllium underclosely controlled conditions causes grain refinementand reduces property directionality. Incorporating a well engineered schedule of cold work and annealing cycles into our mill process ensures a product with precise dimensions and a well controlled microstructure.

Age HardeningAge hardening response depends on time, temperature,and amount of cold work because strengthening isgoverned by precipitate size and distribution. For eachalloy there is a temperature-time combination that isdesignated as standard practice because it producesmaximum strength.

Departures from standard practice, either higher orlower temperatures for example, may be used to meetrequirements that permit less than maximum strengthor hardness. A temperature higher than standard caus-es more rapid precipitation and thus faster strengthen-ing, while a lower temperature results in a slowerstrengthening rate.

Cessation of aging at times shorter than the timeneeded to achieve peak strength is known as “underaging”. Toughness, fatigue strength and in some cases corrosion resistance, benefit from theunderaged microstructure.

“Overaging” involves heating for a time longer thanneeded to achieve peak strength. This results in precip-itate coarsening and consequently in hardness andstrength below peak values. Electrical and thermal conductivities, and dimensional stability are maxi-mized by overaging. Caution is required to avoidsevere overaging.

Age hardening normally does not require eithercontrolled cooling or a special furnace atmosphere. A

protective atmosphere is useful however, especiallywhen it is recirculated to reduce furnace thermal gradients. A low dewpoint atmosphere of 5 percenthydrogen in nitrogen is an example of one that economically aids heat transfer while minimizing posthardening cleaning requirements. Vacuum age harden-ing is difficult because of the nonuniform nature ofradiant heating.

Age hardening increases the density of the highstrength alloys slightly as a result of the precipitationreaction. This density change is accompanied by adecrease in linear dimensions of approximately 0.2%.The dimensional change in high conductivity alloys isnegligible for most applications.

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Fixtures may be used for age hardening to pre-vent distortion. A salt bath provides the precisecontrol needed for short-time high-temperatureaging that results in minimum distortion and theproduction economies of a short cycle.

Residual stress, which may arise from certaintypes of deformation after age hardening, may bethermally relieved without loss of hardness.Heating at temperatures of 300 F to 400 F for upto two hours is generally adequate to providemoderate stress relief.

High Strength AlloysThe standard age hardening treatment for Alloy25 is 600 F for 2 to 3 hours; two hours for coldworked and three hours for annealed products.Representative Alloy 25 age hardening curves at500 F, 600 F , 700 F and 800 F in the annealed,half hard and full hard conditions are shown inthe figures on pages 26 and 27. Several featuresof these curves are reviewed in the following:

First, age hardening at 600 F - 625 F producesmaximum strength for all tempers. Higher tem-perature achieves peak strength in shorter time,but the peak strength is reduced. Heating atlower temperature increases strength at a slowerrate and, although high strength can be achieved,it requires excessive time.

Second, cold work improves the achievablestrength levels for all aging temperatures. As thelevel of cold work increases, the time at tempera-ture to achieve peak strength decreases.

Third, ductility decreases as strength increases.Notice that overaging improves ductility, butthere is evidence that toughness is reduced.

In some applications not requiring maximumproperties, short time high temperature hardeningcycles can be employed. For example, an agingtemperature of 700 F produces peak strength inabout 30 minutes. The temperature-time condi-tions, including heat up and cool down rates, arecritical to hardening rate and intensity.Consequently, when using a special age harden-ing method, the temperature-time should beaccurately established with sample lots beforeproduction begins.

High Conductivity AlloysThe typical age hardening response of Alloys 3and 10 in the annealed condition is shown onthis page. Although the age hardening tempera-tures are different for these alloys than for Alloy25, the same trends hold.

28

Engineering Guide

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product. Cold work plus age hardening pro-duces the highest hardness and strength. Themicrostructure in the HT condition shows theeffect of age hardening on cold worked Alloy25. Standard age hardening does not changethe grain size from that of annealed material.Precipitation of the strengthening gamma phaseis not observable at this magnification.

The high conductivity alloys are character-ized in the A and AT tempers by equiaxedgrains with a fine dispersion of nickel or cobaltrich beryllides. The microstructural features, inthis case for Alloy 3, are somewhat more diffi-cult to develop by etching.

Alloy 25 in the AT temper shows a smallamount of grain boundary precipitate in peak-aged

Aging at 850 F produces maximum strength, but 900F for 2 or 3 hours is commonly recommended becauseof the general need for high electrical conductivity inthese alloys. Increasing aging temperature reduces time

The combined effects of composition, coldwork and thermal treatment are portrayed in the microstructure of copper beryllium.

Microstructural features are revealed on ametallographically prepared sample by etchingwith ammonium persulfate/hydroxide or potas-sium dichromate. The former etchant delineatesgrain boundaries in all tempers and displayscold work effects in age hardened material. Thelatter etchant enhances the contrast of beryllidesbeyond the as-polished condition. Metallographicexamination can thus be tailored to the process-ing conditions of the material.

The microstructure of solution annealed Alloy25 (A temper) reveals an equiaxed grain struc-ture with uniformly dispersed cobalt beryllides.The H temper microstructure for Alloy 25 showsthe effect of a cold rolling reduction of 37% ofthe original thickness on the grain structure.Cold working elongates the grain structure inthe working direction.

to reach peak strength and the achievable strength isdecreased. As time increases, elongation falls whilestrength increases markedly. Beyond two hours therate of change in ductility becomes negligible.

Microstructures

A bright field transmission electron micrograph(TEM) of Alloy 25 shows strain fields associatedwith precipitates. These precipitates are responsi-ble for strengthening. They form initially asGuinier-Preston zones, pass through several stagesof increasing tetragonality, ultimately ripening intothe equilibrium gamma phase.

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Engineering Guide

Surface oxides take two forms: beryllium oxide,present on surfaces exposed to the high tempera-tures needed for solution annealing; and combina-tions of beryllium and copper oxides, present onparts after precipitation hardening. The removal ofa pure, continuous beryllium oxide will not be con-sidered here since solution annealing is rarely per-formed by the user. For special cases, such asremoval of oxides formed during annealing or weld-ing, contact Brush Wellman for appropriate cleaningprocedures.

The surface of copper beryllium can be preparedfor plating or joining, or simply restored to its original, lustrous appearance, with the followingprocedure.

Step 1– Immerse parts in a 120F - 130F aqueoussolution of 20-25 volume percent sulfuric acid plus2-3 volume percent hydrogen peroxide. Immersiontime should be that required to remove dark col-oration and provide the desired response or appear-ance.

Step 2 – Rinse thoroughly and dry.

When necessary, parts made from mill hardenedmaterial can be readily cleaned by the abovemethod. In all cases care should be taken to avoidexcessive immersion time or high acid concentra-tion since these may remove measurable amounts of metal.

Electroplating, Coloring and PolishingNickel, gold, silver, tin, chromium, copper, andother metals are commonly electroplated on copperberyllium. Brush Wellman supplies electroplatedstrip, or can direct an interested user to an experi-enced supplier for discrete part, electroless, orselective plating. Some frequently used plating pre-treatments are as follows.

Alloys other than M25:

Step 1 – Cathodically clean with a hot alkaline solution.

Step 2 – Rinse in cold water.

Step 3 – Immerse for 10-15 seconds in a 120F -130F aqueous solution of 20-25 volume percent sulfuric acid plus 2-3 volume percent hydrogen peroxide.

Step 4 – Rinse in cold water.

Cleaning and FinishingCopper beryllium displays all the desirable plating andjoining characteristics for which the copper alloys arewell known. However, because copper beryllium is frequently specified for precision applications, surfacecleanliness should be considered a critical factor whenarticles are to be plated, or joined by soldering, braz-ing or welding. All foreign substances, including oil,grease, paint, dust, dirt, tarnish and oxide, must beremoved before these operations are undertaken. Thiscannot be emphasized too strongly because most prob-lems related to plating or joining quality can ultimatelybe traced to improper or inadequate cleaning.

CleaningThe first step in the preparation of copper beryllium forsubsequent plating or joining is the removal of all soils,particularly oils and greases. These are normally pres-ent as residual traces of lubricants used during formingor as contaminants from exposure to oil-mist-ladenshop atmospheres. Sulfur-bearing lubricants, if notremoved quickly, can stain copper beryllium. Surfacesoils also result from handling; fingerprints and oilywork gloves are notorious offenders.

Conventional cleaners, such as organic solvents, andalkaline solutions, are normally adequate for removingoily residues. Normal care should be taken to insurethat solution concentrations, temperatures and flowrates are within proper limits and that recirculation orfiltration systems are adequately maintained. Vapordegreasing is especially effective for removing oils andgreases. Trisodium phosphate and similar alkalinesolutions, including the many available proprietary for-mulations, are likewise satisfactory, and ultrasonic orelectrolytic agitation can supplement these media forbest results. Cleaning solutions should be thoroughlyrinsed from all surfaces. Any questions regarding acleaner’s effectiveness should be resolved by testing onrepresentative copper beryllium samples.

Like all copper alloys, copper beryllium can form athin surface oxide, or tarnish, when exposed to air .Tarnish formation is accelerated by the presence ofmoisture and elevated temperature. Oxidation normal-ly results from heat treatment. Even when protectiveatmospheres are used, the formation of sufficient sur-face oxides to cause plating or joining problemsshould be anticipated. Mill-hardened strip however, isthoroughly cleaned and inhibited before delivery.

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Alloy M25

Step 1 – Cathodically clean with a hot alkaline solution.

Step 2 – Rinse in cold water.

Step 3 – Immerse for 10-15 seconds in a room temper-ature 10 to 12 volume percent fluoboric acid aqueoussolution.

Step 4 – Optionally apply a cyanide copper strike foradhesion as recommended for most copper alloys.

Copper beryllium products can also be colored byall conventional techniques used for copper alloys.Satin black oxide to an artificial patina are examples.

Wet brushing, buffing and electropolishing are usedto produce extremely fine surface finishes on copperberyllium. Best electropolishing results are obtainedwith a nitric acid/ methanol electrolyte at -70F. Aphosphoric acid, chromate electrolyte can be used atroom temperature, but this may leave certain inter-metallic particles in relief. Phosphoric, nitric, andacetic acids can be mixed to produce a chemical polishing solution for use at 160 F .

Soldering and brazing are important assembly tech-niques for copper beryllium. As with any precipitationhardening alloy, heating time and temperature duringjoining must be standardized and controlled.

Welding copper beryllium offers advantages overother structural alloys particularly those depending oncold work for strength. In copper beryllium, a weldedjoint can retain 90 percent or more of the base metalmechanical properties. Sensitization, surface depletion,and other difficulties associated with welding otheralloys are not problems with copper beryllium.

SolderingSoldering is normally specified when the anticipatedservice temperature is below about 300 F and electri-cal and thermal continuity are difficult to insure with amechanical joint. Soldering lends itself to automationand can be performed by heating with resistance,induction, infrared, or flame. Application techniquesinclude immersion, wave, vapor phase and others.Copper beryllium can be soft soldered after age hard-ening without detriment to mechanical properties.

Copper beryllium can be soldered with most stan-dard fluxes but flux should never be relied upon as asubstitute for a proper cleaning treatment. Activatedrosin fluxes (RMA or RA grades) are recommended butthese should be removed by hot water rinsing after sol-dering to prevent corrosion of other components.

It is good practice to join parts as soon after surfacepreparation as practical. If delays are unavoidable partsshould be stored in clean, dry locations free fromacidic, sulfurous or ammoniacal fumes. Shelf life canbe extended by inhibiting the surface with benzotria-zole (BTA), or by precoating with pure tin or tin-leadsolder.

Copper beryllium is solderable with all common sol-der compositions. Alloys containing 60% tin-40% lead(60/40) are generally recommended for electronicassemblies, especially when high speed processes areemployed. Hand soldering allows latitude in solderalloy selection and all-purpose 50/50 tin- lead, amongothers, may be used.

BrazingCompared with soldering, brazing provides higherstrength and superior resistance to thermal exposure atmoderately elevated temperatures.

Since brazing is performed at relatively high temper-ature, it is preferable that parts be brazed before agehardening. With a rapid brazing cycle hardened cop-per beryllium can be joined effectively. Time at tem-perature should be the minimum needed to insurebraze alloy penetration.

Surface cleanliness is important for achieving soundbrazed joints. The surface must be free from all tracesof dirt and oil and should be cleaned prior to brazing.A 15 percent to 20 percent nitric acid solution inwater, followed by thorough water rinsing works well.Brazing may lightly oxidize exposed surfaces. Thisoxide can be removed by immersion in 50 percentsodium hydroxide at 265 F, followed by normal acidcleaning.

Furnace, induction and torch brazing are commonmethods. Braze integrity depends on geometrical fac-tors such as joint design, assembly size, and thermalparameters such as heat input and dissipation rates.Heat sinks may be used to confine heat to the jointarea. Small brazed assemblies may permit short timehigh temperature age hardening to be incorporatedinto the brazing cycle. However, the brazing cycle

Joining

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Engineering Guide

tools and cutting fluids are used. Guidelines foreffective metal removal are provided in the table onthis page.

Copper beryllium can be machined at metal removalrates as high or higher than published values for free-cutting copper alloys or stainless steels. This can bedone without sacrifice in tool life provided that proper

Machining

(below age hardening temperature), weld technique,and post welding practice.

Copper beryllium is easily resistance welded by spotor seam welding to itself or other metals. Laser andultrasonic welding are also performed.

Fusion welding by tungsten arc inert gas (TIC), metalarc inert gas (MIC), plasma-arc, and electron beam areroutinely performed on copper beryllium. Post weldingthermal hardening treatments are common unless max-imum strength in the joint area is not required, aswhen the joint is made in a low stress area.

must be kept short to avoid overaging. Larger furnacebrazed parts require quenching after brazing to permitsubsequent age hardening. The brazing temperatureshould not exceed the solution annealing temperature,1450 F for high strength alloys and 1600 F for highconductivity alloys.

WeldingWelding is a useful joining process for copper berylli-um but careful metallurgical planning is essential.Consideration must be given to joint design, preheat

Recommended Speeds and Feeds for MachiningBrush Wellman Copper Beryllium Alloys

Cutting Speed, Feed, Depth of ToolOperation ft/min in./rev Cut, in. Material

Alloys 25, M25 and 165

TurningAnnealed 1500 0.005-0.010 0.025-0.050 C-2Drawn, hard 2100 0.005-0.010 0.025-0.050 C-2Heat treated 2900 0.005-0.010 0.025-0.050 C-2

DrillingAnnealed 200-350 0.002-0.009 – H.S.S.Drawn, hard 150-250 0.002-0.009 – H.S.S.Heat treated 100-300 0.002-0.009 – H.S.S.

TappingAnnealed 50-100 – – H.S.S.

Drawn, hard 30-50 – – H.S.S.Heat treated 10-25 – – H.S.S.

Alloys 3 and 10

Turning 800-1000 0.010-0.025 0.050-0.125 C-2Drilling 125-600 0.002-0.005 – H.S.S.Tapping* 15-150 – – H.S.S.

*Cutting speed is very critical when tapping Brush Alloys 3 and 10.*Cutting speed should be decreased as size of tap decrease.

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HardnessAlthough the tensile test is the official verification ofmechanical properties, hardness is a useful approxima-tion. Hardness testing is essentially nondestructive, itcan be applied to finished components, and the equip-ment is reasonably portable. The hardness of a minia-ture contact, a resistance welding electrode, or an air-craft bearing, for example, can be measured with a rel-atively simple test.

Each hardness test method has a minimum thicknesslimit to its applicability. A test method must thereforebe selected with the gage of the product in mind. The

As with many high performance alloys, machiningcan work harden the surface of a copper berylliumworkpiece. Shallow depth of cut or a dull or rubbingtool can accentuate this hardening. For best results, besure that the tool is sharp and that the feed rate is suffi-ciently high that each subsequent cut penetrates belowthe work hardened layer.

Cutting tools should be sharp and have a positiverake angle between 5 and 20 degrees for best perform-ance. The use of chip breakers for chip control duringturning is recommended.

The use of a cutting fluid as a coolant and for chipremoval is recommended for longer tool life andimproved surface finish. Water soluble oils and syn-thetic emulsions are commonly used coolants.Although the best finishes are obtained from sulfurizedoils, these oils will discolor copper beryllium (andother copper alloys). The stain is not harmful, but itshould be removed after machining, particularly if theparts will be subsequently age hardened.

Copper beryllium also is commonly machined byother conventional methods such as abrasive machin-ing or grinding using traditional equipment. Selectionof grinding wheel, speed, metal removal rate andcoolant follows guidelines established by grindingwheel manufacturers and others. Grinding shouldalways be done wet.

Copper beryllium also is machinable by nontradi-tional methods. Photochemical machining of strip isestablished technology with chemically resistant masksthat were developed specifically for copper alloys.Electrical discharge machining, using either an elec-trode form or a traveling wire, and electrochemicalmachining of all product forms are practiced.

High metal removal rates sometimes presents chipremoval problems with annealed or cold worked product. Long, stringy, tough chips are difficult to han-dle. To avoid this difficulty, copper beryllium is usuallymachined in the age hardened (AT or HT) condition. Inaddition to improved chip control, age hardening andcleaning after machining are eliminated.

Alternately, Alloy M25 in any temper offersimproved chip control due to carefully controlled addition of lead. This alloy is well suited to automaticmachining operations, since the lead in the alloyreduces tool wear and eliminates chip clogging.

Photomicrographs of Alloys M25 and 25 are shownabove for comparison. The presence of lead in M25 ismade visible through special metallographic prepara-tion. The lead is uniformly dispersed and appears asfine particles inside circles which are artifacts of thespecial etching process. Although the presence of leadlimits hot working, it does not affect the response toage hardening, which is identical to that of Alloy 25.

chart on page 34 lists hardness correlations for the testmethods most commonly applied to copper beryllium.

A note of caution, however. Hardness values meas-ured using one test method do not always correlatewell with those from another. Where hardness is criti-cal, as with stamped and age hardened parts, convert-ed values should be avoided. For example, with ahardness specified as Rockwell C37 minimum, makinga Rockwell 15N or 30N test and converting that toRockwell C is less preferable than making the test onthe Rockwell C scale directly. The conversions are

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Engineering Guide - Hardness

useful when hardness is less critical, as it might bewith inspection of incoming raw material.

Diamond Pyramid and Vickers Hardness have theadvantage that a continuous set of numbers covers themetallic hardness spectrum. This test allows hardnessof products of different gages to be compared directly.An important use of microhardness techniques is inmeasuring hardness of foils, fine wires, and other prod-ucts having small dimensions.

Minimium Thickness Requirementsfor Various Testing Methods

Hardness Conversion Table

DiamondRockwell Pyramid

Scales or Vickers Brinell

B and C - 0.040 in.30T and 30N - 0.020 in. 0.002 in. 0.125 in.15T and 15N - 0.015 in.

Diamond DiamondRockwell Pyramid Brinell Rockwell Pyramid Brinell

or Vickers or Vickers

C 15N 30N 3000 kg B 15T 30T 500 kg

48 84.5 66.5 485 460 100 93.0 82.0 240 20147 84.0 66.0 471 448 99 92.5 81.5 234 19546 83.5 65.0 458 437 98 – 81.0 228 18945 83.0 64.0 445 426 97 92.0 80.5 222 18444 82.5 63.0 435 415 96 – 80.0 216 179

43 82.0 62.0 424 404 95 91.5 79.0 210 17542 81.5 61.5 413 393 94 – 78.5 205 17141 81.0 60.5 403 382 93 91.0 78.0 200 16740 80.5 59.5 393 372 92 90.5 77.5 195 16339 80.0 58.5 383 362 91 – 77.0 190 160

38 79.5 57.5 373 352 90 90.0 76.0 185 15737 79.0 56.5 363 342 89 89.5 75.5 180 15436 78.5 56.0 353 332 88 – 75.0 176 15135 78.0 55.0 343 322 87 89.0 74.5 172 14834 77.0 54.0 334 313 86 88.5 74.0 169 145

33 76.5 53.0 325 305 85 – 73.5 165 14232 76.0 52.0 317 297 84 88.0 73.0 162 14031 75.5 51.5 309 290 83 87.5 72.0 159 13730 75.0 50.5 301 283 82 – 71.5 156 13529 74.5 49.5 293 276 81 87.0 71.0 153 133

28 74.0 48.5 285 270 80 86.5 70.0 150 13027 73.5 47.5 278 265 79 – 69.5 147 12826 72.5 47.0 271 260 78 86.0 69.0 144 12625 72.0 46.0 264 255 77 85.5 68.0 141 12424 71.5 45.0 257 250 76 – 67.5 139 122

23 71.0 44.0 251 245 75 85.0 67.0 137 12022 70.5 43.0 246 240 74 – 66.0 135 11821 70.0 42.5 241 235 73 84.5 65.4 132 11620 69.5 41.5 236 230 72 84.0 65.0 130 114

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Fatigue StrengthCopper beryllium strip and wire have a longhistory of success in the cyclic stress environ-ment of electrical and electronic contactsprings. Copper beryllium in heavier sectionsis also used in components subject to cyclicloading. Examples include aircraft landing gearbushings, copper beryllium races and rollers inrolling-element bearings, and oil and gas welldownhole hardware such as anti-galling threadsaver subs.

In these applications an outstanding charac-teristic of copper beryllium is its ability towithstand cyclic stress. Cyclic conditions areproduced by cantilever bending, axial loading,and rotational bending.

Fatigue strength is defined as the maximumstress that can be endured for a specified num-ber of cycles without failure. Low cycle fatiguestrength approaches the static strength. Whenthe number of cycles exceeds one million toten million, the fatigue strength falls to a frac-tion of the static strength. Copper berylliumalloys resist fatigue failure with high staticstrength, toughness, and an ability to diffusestrain by work hardening.

Copper beryllium fatigue curves are provid-ed in the graphs on this page. The ratio ofminimum to maximum stress is termed thestress ratio, “R”. This term, displayed on thegraphs, defines the test conditions. Spring con-tacts deflected in a single direction (R = 0) dis-play a higher fatigue strength than those flexedin reverse bending (R = -1).

Standard tests measure fatigue behavior offlat springs and round beams. Some springmanufacturers have developed their own teststo suit their particular design requirements.Agreement among testing methods is generallygood.

These data serve as a guide, since fatigueperformance depends on the surface conditionand service stress state. Care should be takento insure high surface quality, particularly atedges and fillet radii, to take maximum advan-tage of these important alloys.

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Atmospheric Resistance and Shelf LifeIn environments encountered during production, stor-age, and use of electronic or electrical apparatus, cop-per beryllium alloys exceed the corrosion resistance ofmost specialty copper alloys.

Resistance to tarnish is critical since many electroniccomponents are soldered after extended storage.Surface inhibition with benzotriazole (BTA) reducesoxide formation and extends shelf life. For optimumsolderability, copper beryllium may be coated with tinprior to storage.

Marine EnvironmentsCopper beryllium is well suited for both fresh and saltwater because of a low corrosion rate and an inherentresistance to biological fouling. At low velocity, thecorrosion rate of copper beryllium in sea water is lowand comparable to the cupronickels. High velocityaccelerates corrosion of copper beryllium and mostcopper alloys.

Undersea communication cable housings have seenmore than thirty years of undersea service without evi-dence of fouling or detrimental corrosion. These aremade from copper beryllium because of its excellentstrength, machinability and resistance to corrosion andfouling.

Processing EnvironmentsGlycols, alcohols, esters, ketones, hydrocarbons andmost organic solvents are routinely handled with cop-per beryllium. The sensitivity of copper beryllium toimpurities contained in these liquids is usually greaterthan sensitivity to the organic itself. For example,traces of sulfides, water, acids, alkalis or salts mayaccelerate corrosion.

Curing polyvinyl chloride (PVC) and room tempera-ture vulcanized silicone (RTV) plastics can producefumes, such as HCL and acetic acid, that can corrodecopper beryllium and other copper based alloys.However, copper beryllium is used successfully inthese applications by limiting the production of thesecorroding fumes. The curing of other plastics, such asacetal, nylon and polytetrafluoroethylene (PTFE), emitsvolatiles under similar conditions, but these fumes donot affect copper alloys.

Copper beryllium alloys are compatible with aque-ous solutions of most alkali hydroxides, hot or cold.However, many copper alloys, including copper beryl-lium, are not suitable for handling ammonium hydrox-ide, which promotes stress corrosion cracking. Copperberyllium alloys should not be in contact with ammo-nia unless it is dry and oxygen free.

The alloys resist corrosion in cold concentrated sul-

furic acid; hot or cold dilute sulfuric acid; hydrofloricacid; or cold dilute hydrochloric acid. However, likeother copper alloys, copper beryllium is not recom-mended for structural components that are exposed toconcentrated oxidizing acids such as nitric. Non-oxi-dizing acids such as hydrochloric and sulfuric are cor-rosive when they contain oxidizing impurities.

Copper beryllium is immune to stress corrosioncracking caused by chloride ions, unlike stainless steelthat can crack in just a few hours under high chlorideconditions. This immunity makes copper berylliumideal for applications in oil well environments.Copper beryllium resists hydrogen embrittlementunlike titanium alloys, steels, and nickel base alloysthat are highly susceptible, at comparable strength.

Copper beryllium is susceptible to delayed failure byliquid metal embrittlement by mercury. Strengtheningby either cold working or age hardening increases thissusceptibility.

Corrosion Resistance

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Engineering Guide

Copper Beryllium Service Environments:• Industrial – shelf life sufficient for solderability

to 18 months• Urban – sulfidation resistance up to five times

that of copper• Static Sea Water – less than 2 mils per year• Biofouling – proven resistance, with more than

thirty years exposure• Saturated Chlorides – immune to cracking in

sodium, potassium, magnesium and mixed salts• Hydrogen – no effect on ductility or strength

after cathodic charging at 90°F for more than100 hours

• Organics – compatible with most solvents,although impurities may cause corrosion

• Organic Fumes – resistance should be evaluated case by case

• Dilute Acids and Alkalis – may be used withcaution

• Concentrated Oxidizing Acids – not recom-mended for use

• Ammonia – resistant to attack by anhydrousammonia, but presence of moisture and oxygen promote stress corrosion cracking

• Mercury and other liquid metals - avoid contact

• Other – attacked by ferric chloride, ferric sul-fide, acid chromates, ammonium hydroxide and mercury compounds

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Other AttributesCopper beryllium often is used because it provides acombination of attributes meeting specific needs of auser’s application. Examples include elastic compli-ance and formability (electronic connector contacts),fatigue strength and electrical conductivity (switchcontacts), and hardness and thermal conductivity(resistance welding electrodes).

Copper beryllium has many more useful attributes ofwhich the designer should be aware. Several are high-lighted below.

Nonsparking – One of the oldest and best known usesfor copper beryllium is in hand tools for industrialprocesses where a spark is not permissible. A hot, cop-per rich particle dislodged on impact cools rapidly anddoes not ignite. In addition to spark resistance, copperberyllium has hardness to provide lasting durability.

Nonmagnetic – Brush Alloy 25 has magnetic perme-ability between 0.997 and 1.003 at a field strength of1000 gauss. (A permeability of unity represents perfecttransparency to slowly varying magnetic fields.) Thisproperty is unaffected by cold work in contrast to othernonmagnetic alloys that can become magnetically“hot” during machining, forming or rigorous service.Combined with high strength, fracture toughness, andprecise dimensional stability, these properties lead toexcellent service in magnetic instrument housings,magnetic support structures and other systems.

Galling Resistance – Copper beryllium has inherentlygood wear resistance, allowing contact with othermaterials with a minimum of friction and surface dam-age. Threaded joints of copper beryllium mated toitself or to stainless steel are not subject to galling,even under overload conditions.

Cryogenic Behavior – Copper beryllium is used in liq-uid hydrogen and liquid oxygen due to its ability tomaintain strength and toughness in cryogenic condi-tions. Copper beryllium has no ductile to brittle transi-tion temperature, as do many high strength steels.

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Elevated Temperature Strength – Copper berylliumAlloy 25 demonstrates good stability of tensile proper-ties from cryogenic temperatures through 500 F despitelong exposure. When tested at elevated temperature atconventional strain rates, tensile properties retainessentially room temperature values through 500 F.

The high conductivity alloys retain strength throughabout 600 F. The hardness of these alloys leads to theiruse in welding electrodes and mold components forplastic injection.

Reflectivity – Copper beryllium polishes readily to anoptical mirror surface. Because of its color, this surfacereflects light efficiently, especially in the infrared spec-trum. Reflectivity, machinability and dimensional sta-bility lead to its use in mirrors, particularly where cen-trifugal or other stresses are present.

Dimensional Stability – Besides increasing hardnessand strength, age hardening can relieve stress in cop-per beryllium. This results in high dimensional stabilityduring machining or stamping. A conventional stressrelief that does not alter strength, and various stabiliz-ing thermal treatments are used.

Special Surface Treatments – Surface modification ofcopper beryllium creates several unique possibilities.An oxide formed at high temperature greatly increasessecondary electron emission. Various technique havebeen used for local hardening. Laser and electronbeam techniques have produced various surface states,ranging from localized solution annealing to glazing.Coatings have been applied for increased emissivity,hardening or appearance.

Appearance – The golden luster of high strength alloysand the coral tinted gold of the high conductivityalloys give copper beryllium an attractive appearance.These alloys are polished and waxed or lacquered forapplication as decorative components.

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Engineering Guide - Other Attributes

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YourSupplierThis is Brush Wellman 40

Mining and Manufacturing 41

Service Centers 42

Safe Handling 43

Brush Wellman’s quality commit-ment exists throughout our fully verticallyintegrated corporation. Our commitmentextends from the mining of beryllium ore tothe manufacture of finished materials includingpure beryllium, the oxide ceramic, and numerousalloys on precise and efficient equipment.

This section summarizes a few facts about Brush Wellman,namely; history, corporate profile, mining and manufacturing,distribution, customer service, and quality. Safe handling of beryllium-containingproducts is addressed in a special section. More information is available for the asking.

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This is Brush Wellman Inc.

Company HistoryBrush Wellman Inc.’s historical roots extend back to

1931 when its predecessor company, The BrushBeryllium Company, was founded in Cleveland, Ohio tocommercially develop the beryllium technology of BrushLaboratories. Brush Laboratories was started in 1921 byCharles Brush, Jr. and Dr. C. Baldwin Sawyer, who pio-neered work in the extraction of beryllium from ore andthe production of beryllium metal, oxide and masteralloys.

In the late 1940’s, the Atomic Energy Commission(AEC) developed interest in beryllium powder metal tech-nology and became the first significant user of metallicberyllium and beryllium oxide. During the 1950’s, com-mercial applications for beryllium-containing materialsgrew, particularly copper beryllium. In 1953, BrushWellman built a small commercial plant at Elmore, Ohioto produce copper beryllium alloys. That facility is nowthe largest and most advanced facility for beryllium andberyllium-containing alloy production in the world.

In 1958, Brush Wellman purchased Penn PrecisionProducts Company of Reading, Pennsylvania. This acqui-sition provided Brush Wellman the capability to supply afull range of copper beryllium rolled strip products. TheReading facility now provides world class beryllium- con-taining strip, rod and wire alloys to meet the demand forthese products.

During the 1960’s, Brush Wellman acquired exten-sive mineral rights in the Topaz mountain area of Utahand developed techniques for extracting beryllium fromthese bertrandite deposits. These ore reserves are suffi-cient in size to accommodate the global demand forberyllium and beryllium-containing alloys well into thefuture, and make Brush Wellman the only fully integratedproducer of beryllium, beryllium-containing alloys andberyllia ceramic.

Brush Wellman’s international organization wasestablished in the 1980’s with the formation of BrushWellman GmbH (Stuttgart, Germany); Brush WellmanLtd. (Theale, United Kingdom); and Brush Wellman JapanLtd., (Tokyo, Japan). In 1992, Brush Wellman Singapore(Pte) Ltd. was formed to provide local service and distri-bution in Southeast Asia. In the 21st Century, additionaldistribution, service and sales organizations in HongKong, China, and Taipei, Taiwan have been establishedto serve the growing Asian markets.

In May 2000 Brush Wellman Inc. became a wholly-owned subsidiary of a newly created holding company,Brush Engineered Materials Inc. In addition, the foreignsubsidiaries became wholly-owned subsidiaries of BrushEngineered Materials Inc.

Corporate ProfileBrush Engineered Materials Inc. (NYSE-BW), with

headquarters in Cleveland, Ohio, is the sole parent com-pany of Brush Wellman Inc. Its subsidiaries make the following products:• Metallic beryllium , a lightweight metal possessing

unique mechanical and thermal properties. Its specificstiffness is much greater than other engineered structur-al materials such as aluminum , titanium, and steel.Beryllium Products, including AlBeMet and E-materials,are primarily, but not exclusively, used in the defenseand aerospace markets. Brush Wellman’s metallicberyllium is produced in Elmore, Ohio. Fabricatedcomponents are made at Electrofusion Products inFremont, California.

• Beryllium-containing alloys, including copper berylli-um, nickel beryllium and aluminum beryllium, metal-lurgically tailored to meet specific customer perform-ance requirements. Beryllium alloys are used fordemanding applications in computers, telecommunica-tions, automotive electronics, aerospace, oil explo-ration, undersea and marine environments, and plasticmold tooling.

Alloy Products are produced at the Elmore, Ohio andReading, Pennsylvania manufacturing sites. Distributionservice centers are operated in Fairfield, New Jersey;Warren, Michigan and Elmhurst, Illinois. Research &Development laboratories are situated in Cleveland,Ohio, Elmore, Ohio and at several other global loca-tions.

• Beryllia Ceramic (BeO), a high strength electrical insu-lator with thermal conductivity greater than many met-als. BeO is used in high power electronic circuitry,laser equipment and microelectronics packaging. BeOis produced by the BEM subsidiary, ZentrixTechnologies Inc., at facilities in Tucson, Arizona andNewburyport, Massachusetts. Electronic circuits andpackages are designed and manufactured at the ZentrixCPT facility in Oceanside, California, using proprietaryprocesses to deposit thick film precious metal circuitryonto ceramic substrates.

• Other High Performance and Precious Alloys producedby Brush Engineered Materials’ subsidiaries, includingthe copper-nickel-tin spinodal alloys produced at theBrush Wellman Lorain, Ohio facility. High strength,lubricity, durability, corrosion resistance and thermalconductivity make these copper alloys a premier choicefor plastic molding cavities and cores, heavy duty bush-ings and other severe service applications.

Brush Engineered Materials subsidiary TechnicalMaterials Inc. (TMI) located in Lincoln, Rhode Islandproduces inlay/overlay clad, electroplated and otherspecialty hybrid strip products in a wide range of alloys.

Brush Engineered Materials subsidiary WilliamsAdvanced Materials Inc. (WAM) located in Buffalo,New York supplies high purity specialized metal products for the electronic industry, including vapordeposition materials, clad and precious preforms, high-temperature braze materials, frame lid assemblies andultra-fine wire.

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Your Supplier

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Brush Wellman begins production of beryllium con-taining alloys at its Topaz-Spor mining operation inUtah. Here the company operates the only bertranditeproducing mine in the free world. Bertrandite ore ismined from open pits, and provides a constant sourceof ore for Brush Wellman’s extraction facility in nearbyDelta, UT. At Delta, the bertrandite ore is processedinto a fine powder of beryllium hydroxide.

This hydroxide is transported to the Elmore, OHmanufacturing plant where alloy production begins.

ElmoreThe Elmore, OH plant is the primary thermo-mechani-cal processing facility for the Alloy Division.Metallurgical and metalworking processes include:

• Reduction of beryllium hydroxide

• Melting and casting

• Hot and cold rolling

• Hot extrusion

• Cold drawing

• Annealing and precipitation heat treating

• Cleaning

• Flattening

• Straightening

• Sawing

• Strip plating

• Machining

The products of Elmore manufacturing are: strip,wire, rod, bar, tube, extruded shapes, custom products,plate, casting ingot, and master alloy. These productsare delivered worldwide to service centers for deliveryto customers or to the Reading, PA finishing plant forfurther processing.

ReadingThe Alloy Division’s Reading, PA facility produces fin-ished gage strip and wire products. A variety of metal-working processes are used:

• Rolling

• Drawing

• Pickling

• Annealing

• Precipitation hardening

• Degreasing

• Slitting and welding

• Traverse winding

Some of the most advanced manufacturing tech-niques produce a consistent high quality family ofproducts.

Strip is routinely rolled to thicknesses down to 0.002inch, and wire is drawn to diameters as small as 0.050inch.

The Reading, PA plant is in close partnership withthe Elmore, OH plant. The latter supplies the inputstock that the Reading plant turns into finished prod-ucts. The Alloy Division maintains the highest stan-dards of quality. This dedication to quality is the secretto the success of the Alloy Division and its key to thefuture.

Mining and Manufacturing

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Brush Wellman maintains a worldwide network ofService Centers, Independent Distributors and author-ized agents. People in this network can answer yourinquiry, process your order, and assist with your spe-cial requirements. They are responsive to your requestsfor technical information and have available the com-plete resources of the Brush Wellman organization.

Brush Wellman Service CentersThere are three North American and four InternationalBrush Wellman Alloy Service Centers. Addresses, tele-phone and facsimile numbers are listed on the backcover of this book. These service centers:

• Provide local technical and distribution service tocustomers on all aspects of the use of beryllium-containing alloys, including application engineering,design assistance, safe usage of all the products andalloy selection

• Maintain stock of copper beryllium and other berylli-um-containing alloy products in a wide range ofalloys, tempers and sizes

• Provide rapid delivery of products slit, cut and pack-aged to customer requirements throughout theUnited States, Canada and all international locations

• Provide precision slitting, sawing, leveling, traversewinding and other custom services to meet yourexacting requirements

• Work closely with customers to satisfy individualneeds for import administration, packaging, labelingand special material properties

Brush Wellman Representative Offices:

• Provide local technical and distribution service tocustomers on all aspects of the use of beryllium-containing alloys, including application engineering,design assistance and alloy selection

• Ensure that customer requirements are met by theappropriate Brush Wellman company or BrushWellman Independent Distributor

Independent DistributorsBrush is represented by Independent Distributors inmore than 70 locations in the United States, Canada,Switzerland and in most other countries. The IndependentDistributors make available many of the same productdistribution and technical marketing services of theBrush Wellman Service Centers and provide customerswith a local contact for rapid response, including:

• Maintain local stocking programs of alloy productsfor prompt delivery to their customers

• Have staff that have been trained by Brush Wellmanon the latest developments in beryllium-containingalloys, and can provide local language service forlocal customers

• Provide access to all Brush Wellman resources

Product Distribution

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Product Guide - Strip

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Brush Wellman’s broad coverage of customer serviceis offered through:

• Alloy Sales Engineers

• Regional Alloy Service Centers, with customer service personnel

• Sales and Marketing located in Cleveland, Ohio

A written request or a telephone call to any BrushWellman location will begin the process to satisfy yourrequirements.

Often the need is for Technical Customer Service.When designing a new part, choosing among availablealloys and tempers, interpreting a specification, orweighing component production alternatives, callupon our Technical Service staff in Alloy Marketing.

Brush customer service personnel can draw upon awide range of Brush Wellman resources. Theseinclude:

• Alloy Marketing Technical Staff

• Current technical literature on each product .A technical library with electronic database systems

• Environmental Engineering staff

• Manufacturing and Facilities Engineering personnel

• Custom Fabrication engineering

In addition, Brush people welcome your commentsabout copper beryllium products, ones you are cur-rently using, and those you would like to see devel-oped in the future. Also, since copper beryllium is arecyclable product, we welcome your inquiries aboutcopper beryllium solid or liquid residuals.

Customer Service

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Quality

Brush Wellman is committed to our customers success.Accordingly, we recognize the need to provide highquality products and services as a condition of doingbusiness. The markets we serve include some of themost demanding in the world when it comes to qualityof systems, products and services. We have long beenrecognized for our quality excellence and leadershipby these highly demanding markets.

Our quality initiatives are based on the philosophyof defect prevention and reduction in variability. Wefocus on continuous improvement of our processesand make extensive use of statistical tools.

We believe that continuous improvement requiresemployee involvement and the use of teams. To main-tain high standards of quality, we provide ongoingtraining in quality skills for all employees.

Accordingly, we have a quality policy that guidesthe way we function:

To provide evidence of our quality, we:• Provide material certifications that report test results

demonstrating compliance to customer specifications • On request, we will provide detail of statistical

process capability and product quality• Encourage visits to our operating facilities for the

purpose of auditing our quality systems that meet therequirements of ISO 9002, MIL-I-45208, and A2 LA

We are committed to fulfilling customer needsand expectations through the involvement of allour employees in the continuous improvement ofour products and services.

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Handling copper beryllium in solid form poses no special health risk. Like many industrial materials,beryllium-containing materials may pose a health riskif recommended safe handling practices are not followed. Inhalation of airborne beryllium may cause a serious lung disorder in susceptible individuals.

The Occupational Safety and Health Administration(OSHA) has set mandatory limits on occupational respiratory exposures. Read and follow the guidance in the Material Safety Data Sheet (MSDS) before working with this material. For additional informationon safe handling practices or technical data on copper beryllium, contact Brush Wellman Inc. inCleveland, Ohio at 800-321-2076.

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Safe Handling

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