There are many different ways to join metals together, each with their own advantages and disadvantages. From ensuring the stability of the bond to choosing a method that is quick and efficient, you need to consider a range of factors.
What are welding and bonding?
Welding is a joining method where the metal is heated, allowed to melt together, then fused as it cools. Bonding may use a metal bonding adhesive such as described at https://www.ct1.com/product-applications/metal-to-metal-adhesive/ to attach two metals together. Examples include in the automotive industry, where steel and aluminium parts may need to be joined together.
The following are the main considerations when choosing between bonding and welding.
Efficiency
You want the attachment process to be as quick and simple as possible, in which case bonding may be the better option. Not only can the adhesive be applied faster than the alternatives, it can also be used for other parts of the manufacturing process, such as sealing joints, removing the need for an additional stage.
Durability
A bonded seal will be evenly spread across the metals’ surface, ensuring the uniform distribution of force and therefore a stable connection. If the tension is instead focused on the joining point, as in welding, then that tension puts increased pressure on the bond, meaning it is less strong overall.
Corrosion resistance
One weakness of metals is galvanic corrosion, which can occur when two different metals make contact through an electrolyte. Having a non-metal adhesive barrier separating the two metal surfaces as part of the bonding process means there is no conducting of electricity and the metals will not be able to act upon each other in a corrosive way.
Aesthetics
The adhesive used in bonding is almost invisible, and can be painted over if necessary. It creates a smooth and uniform surface that is aesthetically pleasing, and it can be used to join a wide variety of metals, including those chosen for their aesthetic properties.
In many cases, bonding may be a more efficient joining method than welding, offering a range of potential advantages to consider.