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You need to join metal parts for your industrial application. What is the most reliable adhesive?

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If you need to join metal parts for your industrial application, you might be wondering what is the most reliable adhesive. Adhesives are substances that bond two or more surfaces together by creating a strong and durable connection. However, not all adhesives are suitable for metal bonding, as they have to withstand various factors such as temperature, moisture, stress, and chemical exposure. In this article, you will learn about the main types of adhesives for metal joining, their advantages and disadvantages, and how to choose the best one for your specific needs.

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David Tobler

Strategic Director Marketing Transportation & Marine Business | We help engineers to improve vehicle design and…
Russeen Paul Wali

Scientist seeking work

1 Epoxy adhesives

Epoxy adhesives are synthetic resins that cure by mixing two components: a resin and a hardener. They form a rigid and tough bond that can resist high temperatures, water, solvents, and corrosion. Epoxy adhesives are versatile and can bond different types of metals, as well as other materials such as wood, plastic, or ceramic. However, epoxy adhesives also have some drawbacks, such as long curing time, limited gap filling ability, and sensitivity to surface preparation and mixing ratio.

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Russeen Paul Wali

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Conducting epoxy is remarkably useful for exploratory nanotechnology research due to the typically very strong bond and good conductivity. In cases where an electrical path is not required, epoxies give good adhesion to many surfaces and very strong bonds.

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David Tobler

Strategic Director Marketing Transportation & Marine Business | We help engineers to improve vehicle design and production with adhesive bonding | Sika
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Toughened epoxy adhesives are the standard solution used by basically all car manufacturers for joining metal parts in their body in white assembly. Highly toughened 1C epoxy adhesives allow joining different steel grades or even different metals, increase body stiffness and thus reduce steel thickness and meeting crash requirements. 1C epoxies have the ability to absorb stamping oil and bond to oily bare metal surfaces without special surface treatment.

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2 Acrylic adhesives

Acrylic adhesives are thermoplastic polymers that cure by exposure to air, heat, or UV light. They form a flexible and resilient bond that can withstand impact, vibration, and fatigue. Acrylic adhesives are fast curing and can fill large gaps between metal surfaces. They can also bond dissimilar metals, such as steel and aluminum, without causing galvanic corrosion. However, acrylic adhesives also have some limitations, such as low temperature resistance, high odor, and flammability.

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David Tobler

Strategic Director Marketing Transportation & Marine Business | We help engineers to improve vehicle design and production with adhesive bonding | Sika
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2C Acrylic adhesives are common solutions for metal to metal bonding. They typically bond to metal surfaces without special surface treatment and are fast curing at room temperature. They are widely used for metal bonding applications due to their simplicity in use, they however come with certain limitations: as for most adhesives bond surface must be clean. Many have their Tg (Glass transition temperature) within the service temperature window and may become soft at warm conditions and brittle at cold. This might be an issue if e.g. a bonded part gets exposed to heat in a painting process.

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3 Polyurethane adhesives

Polyurethane adhesives are elastomeric polymers that cure by reacting with moisture in the air or on the surface. They form a soft and elastic bond that can absorb shock and noise. Polyurethane adhesives are flexible and can bond curved or irregular metal shapes. They can also resist water, oil, and abrasion. However, polyurethane adhesives also have some disadvantages, such as low strength, high shrinkage, and sensitivity to humidity and UV light.

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David Tobler

Strategic Director Marketing Transportation & Marine Business | We help engineers to improve vehicle design and production with adhesive bonding | Sika
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Polyurethanes are very versatile materials and grades from highly elastic sealants to high modulus adhesives can be found on the market. Polyurethanes bond well to coated metals but require surface treatments such as primers for bare metal bonding. Elastic polyurethane adhesives are common to join mixed material, e.g. GRP (Glass fiber reinforced plastics) or glass with metal structures. Rigid polyurethanes are mostly used for same material combinations e.g. SMC composite shells with stiffener parts.

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4 How to choose the best adhesive

When selecting an adhesive for your metal joining application, you should take into account the type and condition of the metal, the size and shape of the joint, the expected load and stress, the environmental conditions, and the desired performance and durability. You should ensure that the metal surface is clean, dry, and free of rust, grease, or dirt before applying the adhesive. Additionally, you should check that the application method is easy to use and follow the manufacturer's instructions on mixing ratio, curing time, and temperature. It's also important to consider the bond strength of the adhesive to ensure it can withstand the expected load and stress without cracking, peeling, or failing. Additionally, you should choose an adhesive that can accommodate thermal expansion and contraction as well as any movement or vibration. Finally, you should select an adhesive with an appropriate resistance rating for your application to protect against any environmental factors that may affect the joint.

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David Tobler

Strategic Director Marketing Transportation & Marine Business | We help engineers to improve vehicle design and production with adhesive bonding | Sika
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In addition the process shall be considered. It is important to understand steps following the adhesive joining process. A painting and baking process for example, allow the use of heat curing adhesives or require materials that are resistant to the baking conditions. If assemblies need to be moved quickly after the adhesive bonding step, fast cure systems may be required or the a combination of adhesive and welds or mechanical fastener might be the best option.

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5 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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You need to join metal parts for your industrial application. What is the most reliable adhesive?

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1 Epoxy adhesives

2 Acrylic adhesives

3 Polyurethane adhesives

4 How to choose the best adhesive

5 Here’s what else to consider

Materials Science

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