The Complete Engineering Guide to Bonding Metals with Metal Adhesives

Metal adhesives are an important part of modern engineering because they let you bond things together in a strong, long-lasting, and corrosion-resistant way without the problems that come with welding or mechanical fastening.
Advanced adhesive systems are a reliable, scalable, and cost-effective way to bond steel, aluminium, stainless steel, or metals that are not the same.

What are metal glues?

Metal adhesives are high-performance bonding systems made just for connecting metal substrates to:

• Other kinds of metals
• Plastic or composite
• Surfaces that have been coated or treated

Adhesives, on the other hand, make a continuous bond line that spreads stress evenly across the whole joint, unlike welding or fastening.
This makes connections that are stronger, last longer, and are less likely to break.

Why use glue instead of welding or fastening?

Main Benefits:

• No heat input means no changes in shape or metal properties
• Join metals that are different from each other, like aluminium and steel
• Stop galvanic corrosion
• Stress is evenly spread out (no stress points)
• Do both bonding and sealing at the same time
• Allow for lightweight and multi-material design

Adhesive bonding is becoming more and more common in engineering as a way to join structures.

Core skill: bonding metals that are not the same

The Problem

Bonding different metals is hard for engineers in different ways:

• Different coefficients of thermal expansion (CTE)
• When metals touch, galvanic corrosion happens.
• Problems with adhesion and surface compatibility
• Mechanical stress from vibration and load

The Answer: Bonding with Adhesive

Adhesives help with these problems by:

• Acting as a barrier that keeps metals from touching each other
• Taking in stress caused by differences in thermal expansion
• Extending the life of the service and stopping corrosion
• Making sure that performance is reliable over the long term

Common Uses for Dissimilar Metals

From Aluminium to Steel

• Used in cars and other lightweight structures
• Needs to be flexible and resistant to corrosion

From stainless steel to aluminium

• Common in machines and places where food is safe to be.
• Needs the right surface preparation

Copper to Steel or Aluminium

• Used in electronics and systems that deal with heat
• Needs bonding that can handle high temperatures

Need help with your specific combination? Ask for technical help

Different kinds of metal adhesives

Epoxy adhesives for structures

• Strong and long-lasting
• Very good at resisting chemicals and heat
• Good for applications that need to hold weight

Acrylic Glues

• Quick drying
• High resistance to impact
• Perfect for making things

MS Polymer Flexible Hybrid Adhesives

• Take in movement and vibration
• Best for metals that are different from each other

Anaerobic Adhesives, Adhesives that don't need air

• Threadlocking and holding
• Best for cylindrical assemblies

Important Things to Think About When Designing

1. CTE, or thermal expansion
Different metals expand at different rates. To avoid stress failure, use flexible adhesives.

2. Getting the surface ready
Important for a strong bond:

• Cleaning (getting rid of oil and grease)
• Mechanical wear
• Primers for hard metals

3. Conditions for Loading

• Shear = best
• Peel = very important
• Dynamic loads need flexibility

4. Resistance to the Environment
Think about:

• Weather
• Chemicals
• Wetness

5. Stopping Corrosion
Adhesives keep metals separate and stop galvanic corrosion, which is essential for long-term durability.
 

Welding vs. Adhesives

Applications

Metal adhesives are widely used in:

• Automotive & mobility
• Construction & facades
• Machinery & equipment
• Electronics & thermal systems
• Industrial manufacturing

How to Choose the Best Metal Adhesive

Choosing the right glue depends on:

• Types of metal (same or different)
• Conditions of the load
• Exposure to the environment
• Required flexibility
• Production process

Choosing the wrong adhesive can lead to premature failure.

Help with Engineering

We help engineers and manufacturers with:

• Advice on how to make materials work together
• Suggestions for joint design
• Choosing the right adhesive
   

Contact us

Improving the process

Begin to improve your bonding process

• Lower the chances of failure
• Make things last longer
• Open up new design options

Ask for technical help. 
Talk to an engineer about your application.

Frequently Asked Questions

1. What kind of glue works best on metal?

For load-bearing uses, structural epoxy adhesives are usually the strongest.

2. Is it possible to bond aluminium to steel?

Yes, adhesive bonding is one of the best ways to put these two things together.

3. Are adhesives stronger than welding?

Yes, in some cases, especially when it comes to stress distribution and corrosion.

4. Do I need to get the surface ready?

Yes, you need to prepare properly for bonding to work.