Input billets for extrusions are usually machined from hot-pressed block. The billets are jacketed in mild steel can with shaped nose plugs and are extruded through a steel die between 899°C (1650°F) and 1066°C (1950°F). The jackets are later removed by chemical means. Applications of extruded shapes include boom arms for solar array panels, satellite structures, fuel element cladding, draw stock for wire, and coextrusions with dissimilar metals.

Please note that there are health hazards associated with beryllium, especially when present as airborne particles generated during processing. As with any material, be aware of hazards and take steps to reduce exposure to a safe level.

General beryllium information: Beryllium is one of the lightest metals and has a high strength-to-weight ratio, stiffness-to-weight ratio, and very high specific heat, thermal conductivity, and heat of fusion. It has significant ductility, is readily machined and can be rolled, drawn, or extruded. It finds applications in nuclear reactors (neutron moderator and reflector), X-ray sources/detectors (X-ray transparency), IR target acquisition systems, inertial guidance instruments, computer parts, other aircraft and satellite structures, and heat sink constraining cores. Beryllium is usually produced via a powder metallurgy process to improve machinability and mechanical properties.

Information provided by Materion Corporation (formerly Brush Wellman) and the references.