How to Bond Metal to Metal without Welding

How to Bond Metal to Metal without Welding?

In our day to day lives, we come across tons of different metallic objects, whether it be pieces of machinery or appliances. One common thing we can identify amongst them all is the way they are bonded.

When joining one metal piece to another, the most preferred method is welding. However, don’t let it fool you because there are various other ways you can bond metal to metal without the need for welding.

And in this article, we’ll teach you how to bond metal to metal without welding. Let’s begin.

Ways to Bond Metal with Metal without Welding

Before we dig into the topic of omitting the need for welding when it comes to joining metal components, we need to first figure out why we’re doing so.

Welding is quite an expensive method, and if you’re not experienced enough, getting someone else to do it would require you to break the bank. Furthermore, if you’re near explosive gases or electrical lines, welding could instantly become a health hazard.

We have listed down some alternatives to welding, which will enable you to join your metal components without the need to spend extra money or risk an injury.

Metal Glue

As the name suggests, metal glues are adhesives that you would apply to both the components you want to stick to. It doesn’t end there. There are various different kinds of glues that are specialized for each type of metal composition. The mechanics of adhesives can be different. Some are ineffective on specific metallic compounds while others work with all.

For starters, the most common glue you would find is super glue. This is nothing new to people who have been working with arts and crafts or have had the need to stick broken things back to one piece. Whether it be for metal, wood, plastic, or fabric, super glues are perfect for any sort of household fix. You can also use the glue to fix cast iron without welding.

Moving on, epoxy adhesives have become quite the go-to solution for carpenters and other mechanics as well. These adhesives are placed on both the surfaces to be bonded and then set to dry.

After a certain period of time, the surfaces are brought into contact and held for a brief time to allow the adhesive to solidify and create a long-lasting, durable bond.

And for more outdoor purposes, you should opt for polyurethane glue, which is mostly water-resistant. It’s the ability to handle high temperatures and be unreactive to water that makes it the best option for metal surfaces that come in contact with outdoor weathering.

Soldering

If you’re familiar with working with microchips or other household appliances, then you are no stranger to soldering. The process involves the melting of a metal alloy that fills in between the cracks of metal pieces to be bonded. Upon colling, the alloy solidifies and creates a hard metal bond.

While some may argue this is similar to welding, the process is much simpler and requires less effort. The alloy to be heated requires lower temperatures than welding, and so, it can be done quicker.

In addition, soldering guns are inexpensive and available almost at any hardware store, making them a more affordable option to consider. Although this process is great for fixing your electrical circuits and chips, we would advise against using it for other purposes as the alloy does not produce a highly strong bond.

Drilling Bolts

For beginners, this is the easiest way to ensure a strong and sustainable bond between two metal components. And for the use of bolts, however, you would require a drilling machine.

Nuts and bolts along with the drilling machine are easy to find in hardware stores and can be bought without much confusion. To join the two pieces together, you simply need to align them and drill a hole through both surfaces.

Once you do so, put a bolt through the hole and screw in the nut from the underside, and you’re good to go!

Before you go on to use this method, you must take into account the visibility of the bolt on the surface. As opposed to using adhesives or soldering, the use of bolts requires you to firstly drill through the metal and, secondly, leave a visible bolt head on the surface.

If you’re okay with them both, then this will surely last you for ages, but if you want the surface to be clear of holes or bolt heads, then you should opt for adhesives.

Riveting

This next process is quite similar to the use of nuts and bolts but with a less visible bolt head. Instead of using the large bolts, we use rivets to secure the two metal pieces together. Compared to the previous method, this is also quite inexpensive as the rivets don’t cost as much.

Similar to using the bolts, you will need to drill holes on each of the metal surfaces and align them to place the rivet. The rivet has a thicker end, which holds it close to the drilled hole. Rivets are small less-protruding screws with a cylindrical shaft that thickens as it goes.

When compared to drilling bolts, the difference lies in the diameter of the hole smaller and the visibility of the rivets. This is a great process to use for lightweight metallic objects that are susceptible to impact and vibrations, such as aluminum bars.

Brazing

When we talk about brazing, some people find it to be as complicated of a process as welding, and rightfully so. There are, however, certain differences that make this process much simpler and easier.

Brazing makes the use of a filling agent that is melted at high temperatures and trickled into the gap where the metal components are to be joined. When compared to soldering, this is similar to the alloy that is being used but requires a much higher temperature.

You can consider it to be somewhere between soldering and welding. Once the filling agent solidifies, the metals are strongly bonded together.

Conclusion

While there are tons of alternatives to bonding metals without welding, what matters most is the situation you are in and your requirements.

Some methods don’t provide the strongest of bonds, such as soldering but are perfect for household circuits. And so, you need to analyze the situation and let it dictate your decision in choosing the right method.

Nevertheless, let us know if you liked our guide on how to bond metal to metal without welding.

And, did you know that you can also patch panels without welding. If you want you can check the post on the topic.

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