Structural assemblies of beryllium components can be joined by most techniques such as mechanical fasteners, rivets, adhesive bonding, brazing, and diffusion bonding. Fusion-welding processes are generally avoided because they cause excessive grain growth and reduced mechanical properties. Beryllium behaves like other light metals when exposed to air by forming a tenacious protective oxide film that provides corrosion protection. However, the bare metal corrodes readily when exposed for prolonged periods to tap or seawater or to a corrosive environment that includes high humidity. The corrosion resistance of beryllium in both aqueous and gaseous environments can be improved by applying chemical conversion, metallic, or nonmetallic coatings.
Beryllium can be electroless nickel plated, and flame or plasma sprayed.
However, beryllium powder is toxic if inhaled. Since airborne beryllium particles and beryllium salts present a health hazard, the metal must be machined in specially equipped facilities for safety. Machining damages the surface of beryllium parts. The depth of the damage can be limited during finish machining by taking several light machining cuts and sharpening cutting tools frequently or by using nonconventional metal-removal processes. For highly stressed structural parts, 0.002 to 0.004 in. should be removed from each surface by chemical etching or milling after machining.