How To Join Metal Without Welding?

Metal objects are commonly used in our surroundings. There are many things at home that need to be repaired and are thrown away eventually or added to the stack of pending tasks for the weekend just because you cannot run to a welder every day. Welding these at home can be extremely dangerous because it’s an art performed by professional people.

Furthermore, it can make the metal lose strength and affects physically as well. High temperature can also damage the base metal alternating the actual shape. Many people, including me, have gone through this problem over the years now, but finally, we have alternate solutions. These alternatives are now widely being used as well.

Several methods can be used to join metal without welding. They are now becoming common among the people. A few can safely be performed at our homes and almost give the same output as welding. Some methods along with steps and frequently asked questions have been mentioned below. We hope this can help you find a solution to your problem but before that, you must know the types of joints.

How To Join Metal Without Welding?

Epoxy Adhesives:

Epoxy Adhesive

Metal bonding is commonly used in home-based DIY tasks. The simplest way to join the two pieces of metal together is by using epoxy adhesives. This does not have a substantial effect as that of welding but works decently. This is specially manufactured for homeowners who do not have many skills and need to join metals or other non-porous surfaces.

Steps

The following steps can be followed to use an epoxy adhesive to join the metals together firmly:

  • A sandpaper or emery paper is used to smooth out and remove corrosion or oxidation from the metal surface.
  • Then it should be washed with tri-sodium phosphate to get rid of the contaminants.
  • Equal amounts of epoxy and hardener should be mixed in a bowl and applied to the clean, dry surface.
  • Firmly press the metal pieces together and leave them until they cure.
  • It is recommended to wear gloves throughout the procedure and remove the excess for a professional appearance after the curing is done.

Bolting:

If the epoxy does not work out, we can step up and use the bolting method. Mechanical connections are always more robust and do not snap like glue. We need to figure out the shape and sizes of the bolts, and then all is good to proceed. If the result is not as expected, we can always take the metals apart as they were before. Hence it is not a permanent option and can be altered afterward.

Bolting

Steps

It is a straightforward method and can be performed by using a hardware kit present at our homes.

  • A drilling machine and a drill bit of the same size are required as the carriage bolt.
  • For smooth installation, a fluid is applied to the drill bit.
  • A mark should be made on the spot where the bolt must be inserted to make the process more efficient.
  • Evacuation should be done at a slower speed because the tiny metal objects might cause injuries.
  • After the drilling process, the debris should be removed, and the hole should be cleaned with some acetone if available.
  • Now the bolt is installed until the thread reaches the other side of the hole. A washer and nut should be installed with the help of a wrench to hold tightly.

Brazing:

This method is identical to welding, but it does not require the melting of the metal that has to be joined. Here a bond is formed by the fillers to join these metals together. Brazing forms a solid mechanical connection between the two joining metals and can be very effective. It is a critical process because temperature control is essential to achieve the desired results.

Brazing

Steps

For performing a blazing method, one needs to be accurate at measurement.

  • The gap between the two base metals should be precisely measured, ranging from 0.001 to 0.005 inches.
  • The metal fillers joining the base metals shall be cleaned with acidic agents or polishers to eliminate any grease or rust so that the capillary action works appropriately.
  • A coating of flux on the joint is done to protect the metal from oxidation at high temperatures.
  • The joints must be held firmly until they cool down to develop a strong bond.
  • The temperature must be watched throughout, so it does not affect the base metals.
  • The filler rod or wire is sucked into the joint at the right temperature.
  • After the procedure is complete, the whole assembly should be washed with hot water, and a pickling solution can be used to remove the residues.

Soldering:

The soldering method forms an electrical connection between the metals. It is mainly used in circuits and uses a solder that melts when heat is provided. The solder substance is composed of 99 percent of tin and usually appears as a coiled wire. This process might look the same as brazing, but it is performed at low temperatures in electronic devices. Soldering enables a reliable connection in electronic systems such as calculators, transistors, LEDs, etc.

Soldering

Steps

The following procedure can be used to solder the metal:

  • In a wave soldering process, the solder is melted initially by heating the tank where it is present.
  • A fluxing process is carried out to clean the components.
  • A printed circuit board held with metal clasps is placed on the solder, ensuring firm placement.
  • It should be left for some time, allowing the solder to settle evenly.
  • After the completion, the printed circuit board is cleaned with solvents to get rid of the residues.

FAQs

How do you stick metal together without welding?

Several ways are present to stick the metals together without welding. These alternate methods are safe to use, less complicated, and do not even damage the metal surfaces when joining the broken pieces.

Does welding melt metal?

Welding is performed at high temperatures, which not only melts the metal but also damages the surface. The pressure is put, which deforms the original shape causing irreversible damage.

Is brazing as strong as welding?

Yes, brazing is as strong as welding if done correctly. This does not even damage the surface of the base metal but uses a carrier metal to form a joint and melt into the surface. It can sometimes form a mechanical connection stronger than welding.

What is the best adhesive for metal to metal?

The best adhesives to form the strongest bonds between the metals are epoxy adhesives. These come with a hardener and form a long-lasting bond with other metals or even concrete surfaces.

Is a weld the weakest point?

Yes, a weld is the weakest point on the surface of the metal. It can be the failure point because metals tend to change their physical state and lose strength when exposed to high heat temperatures.

Conclusion

Welding is the oldest method to join the metals together, but it can be dangerous and expensive. It forms a powerful bond and requires proper skills. Many alternate methods have been developed that are less complicated, inexpensive, and even done at home sometimes. Some of the alternate methods to join the metals other than welding are explained above in the article. This can give you a clear idea and help you choose the one suitable for joining broken metal pipes at your home. These do not require a lot of equipment and are safe to perform.

About Dave Walker

Dave Walker, a professional welder who has been welding from an early age. Now aims to help others by making them learning skills and finding them new opportunities. He has written for many welding blogs and helped many pursue their welding goals by helping them in choosing the best welding tools of the time.

Leave a Comment