How to Join Aluminium Without Welding

Aluminium is one of the most popular metals used in the world, and it’s no surprise why. Found in everyday items like drinks cans and featuring as a key material in construction and vehicle assembly, this incredibly malleable metal can be rolled, compressed, and finished to suit a vast range of functions. But, when it comes to joining, is it possible to join aluminium without welding?

As one of the UK’s leading suppliers of aluminium and nonferrous metals, we believe we are best placed to explain to you the alternatives to welding aluminium. Read on to find out more.

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Aluminium to aluminium glue

Using an instant adhesive or super glue is arguably the simplest and most hassle-free alternative to welding.

As previously discussed in our Guide to Gluing Metal, we recommend an epoxy glue for a stronger bond. Both an aluminium epoxy glue and watertight epoxy have the ability to bond aluminium to aluminium and contain the right attributes to keep it secure.

Due to the epoxy fumes, however, it's best to use it outside with a face mask and gloves. Additionally, surface preparation is also fundamental as dust and dirt on the metal will interfere with the bonding. We propose degreasing to thoroughly clean the aluminium surface before applying the epoxy.

Brazing aluminium

Brazing is a similar technique to welding but has a subtle difference; whilst welding is a technique that joins metals by melting the base metal to cause fusion, brazing is the process of joining metals by melting and flowing a filler metal into the two metals you want to join together.

For a quick way to braze aluminium, we suggest using a propane torch and some aluminium brazing rods to bond the metal.

Soldering aluminium

Similar to brazing, aluminium can also be soldered, whereby a low melting point metal alloy (solder) is melted and applied to the joining metals to bond once the solder solidifies.

Be aware that, when compared to soldering other metals, soldering aluminium is comparatively more difficult. This is because aluminium oxide (which all aluminium is coated in) cannot be soldered and must be scraped off. Soldering must be done very quickly before more aluminium oxide forms as a result of the heat.

Riveting aluminium

Riveting refers to the forging process of fastening or securing two metals with power by gripping and engaging, with the use of a metal fastener called a rivet. There are many types of rivets available, and it's key that holes are punched or drilled in the metals to ensure the rivets can fit. Depending on the thickness of the aluminium, riveting can be done manually or by using a machine like a pneumatic hammer.

Purchase your aluminium online

Clickmetal specialises in the online supply of aluminium and other nonferrous metals. We cut down all metal to size and supply across the United Kingdom to both the trade and to domestic customers.

Choose from our wide range of aluminium and stainless steel. Order online today for bespoke sizing and quick, nationwide delivery.

For more information, get in touch via our contact form or give us a call on 01794 526090.