how to bond metal to metal without welding

We live in an incredible world, and everything is possible here if you are determined to use your mind. Bonding two metallic pieces together without welding sound disturbing because all our lives we have heard of welding as the only way for bonding.

Welding is a very common way to connect to metal articles, but welding is sometimes not the only way. Those who think they should start assembling and bonding metallic pieces at home should learn these simple and fantastic ways to connect metal with metal.

how to bond metal to metal without welding

How to bond metal to metal without welding

In this article, I will discuss the following three options and explain the pros and cons of each so that you must get an idea about the alternative methods.

  • Epoxy
  • Brazing
  • Bolting

Bonding metal to metal with Epoxy

Epoxy is a special kind of glue available in any nearby hardware shop, and it is the best non-welding bonding solution for those who want to bond two metal pieces at home.

Here is what to do to bond metal surfaces with the Epoxy glues.

  • Leveling the metal

First, you need to level both the surfaces with sandpaper. It will help you remove all the corroded patches, even if you do not see the corrosions. Still, you must rub the sandpaper merely to level the surfaces.

  • Use trisodium phosphate

You can buy this white powder compound from any nearby chemist’s shop. Before bonding the metal pieces, it is essential to wash them with trisodium phosphate. It is an alkaline substance, so it is safe to use it; however, wearing gloves can reduce harm. In some cases, when you are bonding the pure metal surfaces, it is imperative to wear leather gloves.

  • Put the epoxy in a bowl.

When you open the epoxy glue packaging, you would see that it comes with two tubes, you are supposed to mix these two substances in a separate bowl. Now mix them with a coffee stirrer or a wooden spatula.

  • Apply the Epoxy

Now take both the pieces and hold from the opposite sides of the target area. Apply the paste with a brush. Press both the pieces together and use some good planks to hold the articles. Now, make sure that the items are held in the desired position until the glue dries.

Pros of using Epoxy

  • It is extremely easy to use; you do not need to be an expert in any skill; just simple know-how can help.
  • It dries quickly, in almost 5 to 8 hours.
  • Good for a slight bonding.

Cons of Epoxy

  • It cannot connect two massive objects, like if you want to bond a 1.5 kg metal object with a 3kg article, so technically, it will not be possible with an Epoxy.
  • It is a temporary bonding solution.

Bonding two metal pieces with Riveting

Rivet is a sort of fastener that is a bit different from the bolts. It is not like the standard bolts; you need to fix it in the holes and smash its tail. Here is what you should do for bonding the metal surfaces with the rivets.

  1. First, you should pick up the right type of Rivet, there are several types of rivets available in the market. Pop rivet is the most suitable for fixing two metal articles together. After you have selected the kind of Rivet it is time to check the size.

The pop rivet’s size will depend upon the articles; if you are thinking of connecting two heavy metal objects, then the pop rivet must be larger to balance the tension. You can ask a nearby hardware shop owner about a reliable size for your metal articles. For understanding the size differences of pop rivets, you need to know the diameters.

  1. Get the pop rivet gun; it will come with three or four adapters, where you will fix the pop rivets. Before finalizing a rivet, check the rivets with each adapter and select the one where the Rivet is fixed perfectly. Once you have found the right adapter for the pop rivet, you must remove the set adapter from the gun’s tip and fix the selected one. You can use a spanner for this purpose because the adapters are of the same shape.
  2. Get a hand drill; before drilling any holes, use a caliper to measure the Rivet diameter. Now, change the drilling pin according to the diameter of the Rivet.
  3. Secure the metal pieces that you wish to join while you hold them tightly together. Now, drill from the area where the two pieces are overlapping one another. Once you have drilled a hole in both the metal layers, it is time to insert the Rivet.
  4. Press the pop rivet gun’s handles and continue the procedure until the pop rivets break, and its tail is smashed. The remaining part of the pop rivet, left on the pop rivet gun, can be discarded.

 Pros of riveting/bolting

  • It is the best permeant non-welding option for bonding metals.
  • It is a cheap process, as you are not supposed to buy heavy electronic tools.
  • You can unbind the metal when needed.

Cons of Riveting

  • It is only good for light metal plates.
  • It requires some effort.
  • You need to spend some time and energy.

Bonding metal pieces with Brazing

It is a bit technical, and you need a lighter flame to melt the metal pieces. It is not welding, but it does not require that much heat energy. Here is how you do the Brazing.

  1. You need a wire brush and sandpaper to clean the metals so that it must not heat the corroded areas.
  2. Use clamps to secure the metal pieces together; otherwise, they will not be secured perfectly together.
  3. Get the brazing torch, now heat the two metal layers. Do not overheat it; you will see the red area, and before it turns black, you need to put the Brazing material in between the layers.
  4. Ensure that the Brazing material is not pre-heated because it should melt at the metal layers by their heat. Otherwise, the bonding will not be of high quality, and it will not bear the pressure.
  5. Get a wire brush to clean the area after bonding the two metal pieces; however, wait until it gets a bit cold, or you will stick the wire brush with the heated metal part.

Pros of Brazing

  • It is an easy DIY method; it is a bit tricky, but anyone who has a little knowledge about metals and the use of a brazing torch can apply this method for bonding to metals.
  • It is best if you want to connect two metal pipes, so you may solve the plumbing issues at your home.
  • Best for metals like copper, aluminum, cast iron, nickel, steel, and brass.

Cons of Brazing

  • Not suitable for ferric materials.
  • You cannot use it for the more structured metal pieces.
  • It is a relatively expensive way to bond the metal pieces. As you need to buy the Brazing torch, that will sot you almost 100 dollars, especially if you are buying a beginner’s kit.


If you are afraid that welding can be difficult for you, you can rely on these three ways. They all are the bets for home-based metal bonding. The only requirement for all these methods is a beginner’s kit depending upon the way you have chosen.

Lastly, whatever you do, make sure that you have taken care of the safety measures, and in case of any emergencies, you know the way out. For assurance, you may look around and check if anybody around you is doing the same thing and get some guidance. Using the Above guidelines You can able to join two pieces of metal without welding.