Is Welding the Best Way to Join Metal?

Someone using a welding torch to join two pieces of metal at I.B. Moore Company, LLC near Lexington, KY

Is Welding the Best Way to Join Metal?

The I.B. Moore Manufacturing team members field countless questions every day. Since we’re a manufacturer, fabricator, and distributor of industrial rubber products, many of those inquiries involve welding. A common one is, “Is welding the best way to join metal?”

The answer is a bit involved, but we get it; only some people can access welding equipment or have the necessary training and experience. The easiest way to explain this is to describe various methods for joining metal and their pros and cons.

The Traditional Method: Welding

Welding uses heat to fuse two or more pieces of metal for a strong, permanent bond. It’s for most metals, including steel, aluminum, and copper. Different types of welding, like MIG (Metal Inert Gas), TIG (Tungsten Inert Gas), and stick welding, offer versatility for various materials and thicknesses.

This method is versatile enough for different applications and industries, including construction, automotive, and manufacturing. However, it isn’t ideal for some metals that do not tolerate high temperatures. Welders use industry-grade equipment and must wear protective gear like gloves and goggles.

Joining Two Pieces of Metal Without Welding

Brazing

Knowing how to join metal without welding also requires considerable skill. This first method, brazing, involves melting a filler metal and flowing it into the joint between two metal pieces. Unlike welding, you don’t melt the base metals. Brazing is suited for thin materials that would otherwise warp when welded.

Brazing needs less heat than welding, so there’s less risk of warping, especially with thinner materials. But it’s not as strong as welded joints. Brazing can be less durable under high-stress conditions and might require additional surface preparation.

Soldering

Soldering is similar to brazing but uses a lower temperature and a filler metal with a lower melting point. It’s used in electrical work, plumbing, and small repairs but not for heavy-duty structural applications.

This method for joining two pieces of metal without welding is best suited for electrical and delicate work. It is fairly easy compared to welding and requires minimal equipment. However, the bonds can be weaker; only use soldering for thin metals and low-stress environments.

Riveting

Riveting is a mechanical fastening technique in which a metal pin (rivet) is inserted into a pre-drilled hole to hold two pieces together. Rivets are widely used in industries like aerospace, where they provide a strong, reliable connection without requiring heat. Automated riveting tools make the installation process move quickly.

However, rivets can loosen over time, especially in vibrating environments like moving machine parts. We don’t recommend it for thick materials or projects requiring high tensile strength.

Bolting

Bolting is another process for joining two pieces of metal without welding, using a nut and bolt to hold metal pieces together. This approach is suitable for situations where a temporary or adjustable connection is needed, for thin or thick materials.

Bolting is a heavier, bulky fastening method that requires drilling holes. The connections can loosen over time, especially when the environment vibrates.

Adhesive Bonding

Adhesive bonding involves using a specialized industrial adhesive like epoxy to hold metal parts together. It’s seen in applications requiring lightweight materials or where welding or other methods are impractical. Epoxy evenly distributes stress across a joint; since there’s no heat involved, you don’t have to worry about warping.

This is a weaker bond compared to welding or mechanical fasteners. Also, adhesives can degrade over time, especially under extreme conditions like high temperatures.

So, is Welding the Best Way to Join Metal?

The answer depends on your project’s requirements. Welding provides one of the strongest bonds available for high-stress applications that require long-term durability. However, joining two pieces of metal without welding is more practical for smaller projects or situations where heat could cause damage.

Brazing, soldering, and riveting offer alternatives to welding, with flexibility based on the type of material and the desired outcome. Bolts or adhesives can offer advantages in scenarios where adjustability or ease of disassembly is essential—it’s more of a temporary solution at times.

Adhesives and rivets offer lightweight, flexible connections; when high-strength joints are needed, welding is the superior option.

Turn to I.B. Moore Manufacturing for Quality Products and Trusted Service

Is welding the best way to join metal? You have the explanation, and we can help you with any other questions. Whether you’re looking for durable rubber D-rings or other custom solutions, we offer products that meet the highest industry standards for your fastening needs.

Our team is here to help you find the right solution for your specific project. Contact us in Lexington, KY, for more nationwide service. We answer inquiries in less than two business days, and you can call our team for even faster service.