Beryllium-copper alloy, as a high-performance metal material, is widely used in many fields. Its unique physical and chemical properties, such as high strength, high conductivity, and good wear resistance, have made it highly regarded. The following will introduce the production process and flow of beryllium-copper alloy in detail.

Raw material preparation

The first step in the production of beryllium-copper alloy is to carefully prepare the raw materials. The main raw materials are beryllium ore, copper ore, and some necessary additives. The beryllium ore undergoes beneficiation treatment to increase the grade of beryllium, so as to facilitate subsequent extraction. The copper ore also needs to go through a similar beneficiation process to obtain the required refined ore. The selection of additives depends on the final performance requirements of the product. For example, certain elements can be used to improve the mechanical properties of beryllium-copper alloy.

Melting

l Melting equipment

The commonly used melting equipment is an induction furnace. It uses the heat generated by electromagnetic induction to melt the metal raw materials. The induction furnace has the advantages of fast heating speed and precise temperature control, which can effectively ensure the stability of the melting process.

l Melting process

The pre-treated beryllium ore, copper ore, and additives are added to the induction furnace in a certain proportion. At high temperatures, the ore gradually melts, and various elements begin to mix uniformly. During the melting process, temperature and time need to be strictly controlled to ensure that the alloy composition reaches the expected ratio and distribution. At the same time, to remove impurities, an appropriate amount of flux is added, which forms a slag on the surface of the metal liquid and facilitates separation.

Refining

The alloy liquid after melting may still contain a small amount of impurities, which will affect the performance of beryllium-copper alloy. Therefore, refining is necessary. The refining method usually combines chemical refining and physical refining.

l Chemical refining

By adding specific chemical reagents to the alloy liquid, they react with the harmful impurities, converting them into compounds that are easy to remove. For example, adding certain metal elements can form high-melting-point compounds with sulfur, phosphorus, etc., which can be separated in the subsequent processing.

l Physical refining

The commonly used physical refining methods include blowing gas stirring and filtration. Blowing gas stirring is to introduce inert gas, such as argon, into the alloy liquid to cause vigorous stirring, promoting the flotation and uniform distribution of impurities. Filtration is to remove solid impurities from the alloy liquid through special filtration media, such as ceramic filters.

Casting

After the alloy liquid is refined to the specified composition and temperature, it enters the casting stage. Casting is to pour the alloy liquid into a specific mold to form the required bar.

l Mold preparation

Selecting the appropriate mold according to the specifications and shape of beryllium-copper alloy. The mold material is usually high-strength alloy steel to withstand the high temperature and pressure during the casting process. Before use， the mold needs to undergo strict cleaning and preheating treatment to prevent the alloy liquid from adhering to the mold and ensure the smooth progress of the casting process.

l Casting process

Using gravity casting or centrifugal casting methods to inject the alloy liquid into the mold. Gravity casting is suitable for simple-shaped and large-sized bars. Centrifugal casting uses high-speed rotation of the mold to use centrifugal force to evenly distribute the alloy liquid on the inner wall of the mold， forming a dense billet， suitable for bars with high density requirements. During the casting process， the casting speed and temperature need to be controlled to avoid defects such as air holes and cracks.

Heat processing

The beryllium-copper alloy billets after casting need to undergo heat processing to improve their microstructure and properties. Heat processing mainly includes forging and rolling.

l Forging

Heating the billet to a certain temperature and using forging equipment to apply pressure to cause plastic deformation of the billet. The forging process can break coarse grains， refine the microstructure， and improve the strength and toughness of beryllium-copper alloy. Forging ratio (the ratio of the cross-sectional area of the material before and after forging) is an important parameter. Usually, an appropriate forging ratio is selected based on product requirements, and it is generally between 3 and 5.

l Rolling

Rolling is the process of continuously rolling the forged material through a rolling machine to further reduce the diameter of the bar and achieve the required dimensional accuracy. The rolling process is divided into two stages: hot rolling and cold rolling. Hot rolling is carried out at a higher temperature, mainly to improve the processing performance of the bar and make it have good plasticity. Cold rolling is carried out at room temperature, through which the surface quality and dimensional accuracy of the bar can be improved, and its strength and hardness can also be further enhanced.

Heat treatment

Heat treatment is a key step in the production process of beryllium copper alloys, which can significantly improve the mechanical properties of beryllium copper alloys. Common heat treatment processes include solution treatment and aging treatment.

1. Solution treatment: Heat the beryllium copper alloy to a certain temperature to allow the strengthening phase in the alloy to fully dissolve into the matrix, and then rapidly cool it to obtain an oversaturated solid solution. The temperature and time of solution treatment have a significant impact on the performance of the alloy. Generally, the temperature is between 780 - 820, and the holding time depends on the size of the bar, usually 1 - 3 hours. Rapid cooling can prevent the strengthening phase from precipitating during the cooling process, ensuring the stability of the oversaturated solid solution.

2. Aging treatment: After solution treatment, the beryllium copper alloy is subjected to aging treatment at a certain temperature, causing the solute atoms in the oversaturated solid solution to gradually precipitate, forming dispersed strengthening phases, thereby improving the strength and hardness of the alloy. The aging treatment temperature is generally between 300 - 400, and the aging time is 2 - 4 hours. The temperature and time of aging treatment need to be precisely adjusted according to the specific performance requirements of the product. Surface treatment

To enhance the corrosion resistance and appearance quality of beryllium copper alloys, surface treatment is usually required. Common surface treatment methods include passivation treatment and coating treatment.

1. Passivation treatment: By immersing beryllium copper alloys in a specific passivation solution, a dense passivation film is formed on the surface. The passivation film can prevent chemical reactions between the metal surface and oxygen in the air, moisture, etc., thereby improving the corrosion resistance of beryllium copper alloys. The composition and treatment time of the passivation solution depend on product requirements.

2. Coating treatment: Coating treatment involves depositing a layer of other metals or alloys, such as nickel or chromium, on the surface of beryllium copper alloys. The coating layer can further enhance the corrosion resistance, wear resistance, and decorative properties of beryllium copper alloys. The coating process includes electroplating and chemical plating, and different coating methods are suitable for different product requirements.

Quality inspection

In the final stage of producing beryllium copper alloy, strict quality inspections are necessary to ensure that the products meet the relevant standards and customer requirements. The quality inspection items mainly include chemical composition analysis, mechanical property tests, dimensional accuracy measurement, and surface quality inspection, etc.

1. Chemical composition analysis: Using methods such as spectroscopy analysis, the content of various elements in the beryllium copper alloy is precisely determined to ensure that it falls within the specified composition range as per the design requirements.

2. Mechanical property tests: Through tensile tests, hardness tests, etc., the mechanical property indicators such as strength, toughness, and hardness of the beryllium copper alloy are tested. The results of the mechanical property tests should meet the requirements of the corresponding standards.

3. Dimensional accuracy measurement: Using measuring tools such as calipers and micrometers, the dimensions such as diameter and length of the beryllium copper alloy are precisely measured to ensure that they fall within the specified tolerance range.

4. Surface quality inspection: Through visual inspection or non-destructive testing methods, defects such as cracks and sand holes on the surface of the beryllium copper alloy are checked. The surface quality should meet the usage requirements of the product.

The production of beryllium copper alloy is a complex and rigorous process involving multiple links and processes. Only by strictly controlling the parameters and operations of each link can high-quality beryllium copper alloy products be produced to meet the needs of different fields.