Alternatives To Welding? Comprehensive Guide

Alternatives To Welding

Finding a skilled welder when you have to install a fence in your backyard may be a tough row to hoe as there is a lack of well-experienced professionals in the field. If this is the case, you do not need to worry anymore because there are alternatives to welding. We are going to give you a brief explanation of each of the methods in this article, and at the end, you will find the best option. 

Welding is simply combining metals by using high heat and pressure. Welding can be performed with thermoplastics as well as some types of wood, even though there are some metals that cannot be welded together, like, aluminium and carbon steel, aluminium and stainless steel etc. As a whole, aluminium is the hardest metal to weld. Welding must not be processed without experience and safety kits. 

Alternatives to Welding

Welding is not an easy task and a work that strictly must not perform inside your house. It has been recommended by the law that you should have Local Exhaust Ventilation (LEV) if you are going to do it at home. This is to avoid contact of the involved technicians and the people in the surrounding to dust, toxic fumes and gases expelled during the process. Purchasing and maintaining such a system is way too expensive. If you start welding inside your premises without enough safety precautions, it even has the possibility of ending up with a fire hazard. 

The world has found several alternatives to welding to overcome these issues bounded with welding. Let’s explore them one by one.

Metal Adhesives

Metal adhesives are the glue used to attach metals. These glues are of three types; epoxy adhesives, polyurethane adhesives, and super glues. All the adhesives need to be left for a certain period of drying. A significant drawback here is that we cannot expect the durability of a welded joint in this method. 

Epoxy Type is commonly used in wood. But we can also see the participation of epoxies in metal gates, fixing table legs, repairing kitchen appliances and doorhandle pasting etc. Here it would be better if you could clean the surfaces and sand a little so as to provide a slightly rough surface to adhere effectively.

Polyurethane Adhesives are the best performed when it comes to bonding two metals. This is the best match for you if you intend to use adhesives in an outdoor project. That is because polyurethane-based glues are both waterproof and UV-proof. This will keep your structures stable no matter the weather in every season. 

Super Glues, which are industrially known as Cyanoacrylate glues, can be used in adhering household things like repairing ornaments, car parts etc. 

  1. Brazing 

Brazing may look like welding. But welding does not use a different material in the bonding process. Here in brazing, another material is introduced between the two metallic surfaces. First, the two surfaces are subjected to high heat, and then the filler is added to the space. Most importantly, in brazing, you will have to choose a metallic filler that has a lower melting point than the two metallic surfaces that are going to be joined. 

Copper, Silver, Nickel alloy, and Aluminum-Silicon are some commonly used fillers in brazing. High-intensity brazing torches are used in this process.

  1. Soldering

Soldering is using a filler metal to connect two metals in smaller amounts. The process is performed basically in electrical circuits. The capacity of the project is the fact that differs soldering from brazing. 

  1. Using Hardware

This is the method which connects two metallic sheet surfaces with nuts and bolts. Sometimes screws are also used. The hole is made with a drilling machine matching the nuts and bolts used. The use of washers will reduce the damage to the metal. 

This method is also a low budget, but you cannot expect a long-term last when fixing with hardware similar to the welding. Another significant advantage of this method is being able to complete quickly without must labour and skill.

  1. Riveting 

Riveting is the process that uses a rivet- a mechanical fastener, to connect two metals through a hole. This is named a semi-permanent method. A special machine is used to install rivets. Rivets are of various types and are categorised mainly by placement, number of cover plates and arrangement. 

Considering the placement, rivets are of three types, namely the Lap joint and Butt joint. In lap joints, the metallic sheets are kept to overlap, and the rivet is placed in the overlapped place. Single and double are the two forms in which you can use lap joints. Keeping two surfaces stuck together with extra material and riveting the cover is done here. 

The number of cover plates used in butt joints also makes a difference in the riveting applied on those surfaces, namely single-strap butt joints and double-strap butt joints. In a single strap, one covering plate is used on one side, and consequently, two plates are involved, one on each side in double strap riveting. 

Based on the arrangement, there are two types; chain riveted joints and zig-zag riveted joints. When the rivets are on opposite sides but in a straight line, those are called chain riveted joints. In the zig-zag riveted way, rivets are not in a straight line. 

What are the Advantages of Using Riveting?

The riveting methods do not use heat in the installation of rivets to the metal and are considered the most efficient way to bear heavy loads. But there is a drawback; there could be spaces when riveting two surfaces. Therefore, it is not leakproof.

How Strong is Brazing? 

Brazing is not strong as welding. But, if the process is done with technically correct measures, the built surface has the ability to bear around 70 000 psi.  


In this article, we have described the five alternatives to welding with the mechanisms used in each. You can find the appropriate one based on the nature of your project with the guide we have given here. 

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