The exceptional properties of beryllium (Be) including low density and high elastic modulus, make it the material of choice in many defense and aerospace applications. However, health hazards associated with Be material handling limit the applications that are suited for its use. Innovative solutions that enable continued use of Be in critical applications while addressing worker health concerns are highly desirable. Plasma Transferred Arc solid freeform fabrication is being evaluated as a Be fabrication technique for civilian and military space based components. Initial experiments producing beryllium deposits are reported here. Deposit shape, microstructure and mechanical properties are reported.

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