Lots of welding enthusiasts and DIYers wonder, can you bond metal without welding? The answer is yes, you can, and the bond can be as strong as welding joints.
There are several methods with individual advantages for specific situations or materials. That information leads us to another question.
How to bond metal to metal without welding?
Depending on the material type and fabrication requirements, you can use epoxy, glue, brazing, riveting, soldering, or nut and bolts to bond two metals. Let me describe the methods and show you all the different ways of doing the job.
How To Bond Metal To Metal Without Welding?
All methods on how to attach metal to metal without welding are included in this main section. I have described the steps for each metal bonding without welding technique, listed the eligible metals so that you can choose the right one for your job.
1. Brazing
It is the closest to the welding process and similar to the soldering process. That is why lots of without weld bonding for metal to metal situations demand brazing.
How to braze metal
- Firstly, clean the metal surface. Use a wire brush or emery cloth to rub the targeted spot, and clean that area using soapy water or a degreaser.
- After that, place the other metal to be joined together and you can use clamps to hold it in the place.
- Now, use the torch to heat the joint until the pieces glow.
- Next, bring the brazing rod to the heated area without stopping the torch.
Note: For larger areas, you should pre-heat the spots and then use the brazing rod as the final step.
- Lastly, use a wire brush again to clean the brazed surface so that no oxidation or residue can possibly weaken the joint.
Note: You can use different heating methods besides a torch. It can be laser, electron beam, infrared, dip, induction, or furnace.
What metals are suitable
- Copper, brass, and bronze supports bonding with copper phosphorous brazing rods
- Steel, stainless steel, nickel alloys, copper alloys, cast iron, and tungsten carbide support bonding with nickel silver filler metals.
- Cast iron, galvanized, nickel, steel, and malleable iron braze perfectly with the help of bronze brazing rods.
- Aluminum is also widely brazed and it needs Al3 aluminum brazing rods for the task.
2. Soldering
Soldering is used in different industries, and attaching electrical or electronic components on circuit boards is the most popular of all. Let’s see how to solder two metals together.
How to solder metal together
- Firstly, pick your soldering iron and plug it in for preheating.
- Then, use a resin flux to break the oxide coating on the targeted surface so that the bond doesn’t get weakened.
- Now, place the component in its place and hold the solder wire close to it.
- After that, touch the tip of the soldering iron to the wire. It would melt the wire and set around the component’s metal legs.
- Finally, let it a few moments as the soldering metal cools down very fast.
Note: Plumbing works that involve soldering also use almost the same process but different equipment.
What metals are suitable
- Electrical and electronics components get attached to the circuit board with 99.3% tin and 0.7% copper soldering.
- Plumbing works that involve pipe joining use 97% tin and 3% copper soldering.
- Jewelry works involve joining two metals or repairing them with 76% silver, 21% copper, and 3% zinc.
3. Epoxy
Among different types of glue for metal bonding, epoxy is the strongest glue for metal to metal bonding. It comes with some unique characteristics such as heat resistance and chemical resistance. Epoxies can either be one-part or two-part solutions. The latter one is preferred to be used in metal bonding.
How to use epoxy to bond two metals
- Firstly, take the two pieces of metal and clean the joining surfaces with a woolen brush.
- Then, use a degreaser or multipurpose solvent and clean the chemical with a piece of cloth.
- Next, you can buy a J-B weld, and mix two parts on a plastic nonreactive surface.
- Now, put the mixture on the metal pieces where the bonding is going to take place. Also, clean excessive material.
- Finally, use some sort of support system to hold the pieces together until the solution gets cured.
What metals are suitable
- Aluminum and copper are the metal types that bond well with epoxy glues.
J-B weld and Loctite make the strongest epoxy for metal bonding. Besides brazing, you can use the Loctite Epoxy Weld compound for bonding aluminum to steel and other materials.
4. Acrylic
This metal glue can be of two types; surface activated and bead on bead acrylics. It gets activated when the two metal parts come into contact together with it.
How to use acrylic to bond two metals
- Sand the metal surfaces so that the glue can get a grip on the pieces.
- Take a popsicle stick or toothpick to apply the glue to the workpiece. Put the glue on both pieces.
- Give them a few moments and finally join them together. Let it be like that to cure the parts for 24 hours.
What metals are suitable
- Aluminum, steel, copper, and oily metal surfaces bond well with this type of adhesive.
5. Cyanoacrylate
As instant adhesives or super glues for metal, Cyanoacrylic is very famous in the industry. Among miniature and modeling hobbyists, this is widely used for its unique properties.
How to use acrylic to bond two metals
- The simple application process of this super glue for metals only requires you to clean the surfaces and apply them on one piece. Then, stick both pieces together and it would get cured within a few moments.
What metals are suitable
- Brass and copper are suitable metals to be bonded with Cyanoacrylic.
6. Anaerobic
When you want a strong bond between a thread and a fastener, welding can’t be the solution. Only anaerobic metal adhesives are capable of securing fasteners without needing oxygen to cure.
How to use anaerobic metal adhesives
- Take the fastener and the tube of the adhesive.
- Clean the surface before putting some liquid glue around the fastener.
- Finally, tighten the fastener as fast as you can.
Where to use it
- Though the ideal use of anaerobic metal adhesives is in sealing, it is also very popular in locking threaded metal assemblies.
7. Riveting
Rivets are one of the most popular easy, effective, and permanent ways on how to join metal without welding. After choosing the right rivet size and capacity for your requirements, you should follow the steps below. Rivets can be made of different materials. So, get the right type for your workpiece.
How to rivet metal together
- Drill a hole through the sheets of metal that you need to be riveted. Match the drilling diameter to the rivet’s size.
- Insert the rivet into the freshly made hole, place the stem into the riveting tool, and pump its handle until it pops up.
What the compatible metals are
- Aluminum rivets are for joining two aluminum, and Al/Zn-coated steel pieces together.
- Steel rivets are suitable for Al/Zn-coated steel, and Zinc-coated steel pieces together.
- Stainless steel, nickel-copper, and copper rivets are suitable for stainless steel, copper, and brass pieces together.
8. Nuts and bolts
Just like riveting, nuts and bolts can also be a solution on how to stick metal to metal without welding. It involves drilling into the targeted pieces and tightening them with screwdrivers. You can also use anaerobic glues to make them more secure than usual.
9. New possibility
Another new technology is on its way which hasn’t been matured enough to hit the market. It is a revolutionary method and one of the different ways of joining metal that uses nanomaterials or nanoscale sculpting.
The process begins by roughening the metal surface which works as a hook-like structure on a very small scale. After that, the two of the pieces get bonded with adhesives which later turns into a very solid bond.
It is so reliable that you can use it to join large structures and heavy components. Among lots of its benefits, no requirement of high temperatures and filler material are the most notable ones. As a result, several downsides of welding get eliminated immediately.
Conclusion
I hope that the steps and discussions have helped you know how to bond metal to metal without welding. Now, it would be naive to think that it is possible to complete all fabrication tasks with all those alternatives.
So, which one are you going to try out? I think brazing is the closest to welding but adhesives can work miracles in non-weldable situations.
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