How do you join metal and metal (steel to aluminum)

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Discussion Overview

The discussion revolves around methods for joining two pieces of metal, specifically steel and aluminum, with participants exploring various techniques such as brazing, welding, and the use of epoxy. The context includes considerations of corrosion, material compatibility, and the practical limitations of the participants.

Discussion Character

  • Exploratory
  • Technical explanation
  • Debate/contested
  • Experimental/applied

Main Points Raised

  • One participant inquires about the feasibility of brazing or using silver solder to join steel and aluminum, seeking advice on necessary materials.
  • Another suggests using epoxy resin as an alternative joining method.
  • A participant emphasizes the need for welding due to the specific application involving a bar clamp.
  • Some participants propose making the joint from the same material as the main clamp and using TIG welding, while others note the lack of access to welding equipment.
  • Concerns are raised about the challenges of brazing aluminum, with one participant describing it as a "mysterious art" and suggesting that it may not be worth the effort without prior experience.
  • One participant identifies the materials as zinc and questions their weldability, while another warns about the hazards of burning zinc and suggests a bolt-on solution instead.
  • There is a discussion about the potential for confusion regarding the actual materials, with one participant asserting they are zinc and another suggesting they might be cast iron.
  • Participants discuss the effectiveness of epoxy, recommending surface preparation for better adhesion and cautioning against clamping too tightly.

Areas of Agreement / Disagreement

Participants express differing opinions on the best method to join the metals, with some advocating for welding and others for epoxy or mechanical fastening. There is no consensus on the material composition, leading to further uncertainty about the appropriate joining technique.

Contextual Notes

Participants acknowledge limitations regarding the tools available for welding and the potential hazards associated with burning zinc. There is also uncertainty about the exact materials involved, which affects the proposed methods for joining them.

Who May Find This Useful

Individuals interested in metalworking, particularly those exploring methods for joining dissimilar metals or seeking practical advice on material compatibility and joining techniques.

stinkingbowel
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hi there, i want to connect two pieces of metal together one is i think a piece of steel capable of being attracted by a magnet and the other piece an aluminum piece, or maybe another metal, but not magnetic at all anyway they're both solid pieces and need to be joined. is brazing or using silver solder a good option here? what am i going to need to buy?
thank you
 
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what am i going to need to buy?

Epoxy resin
 


stinkingbowel said:
hi there, i want to connect two pieces of metal together one is i think a piece of steel capable of being attracted by a magnet and the other piece an aluminum piece, or maybe another metal, but not magnetic at all anyway they're both solid pieces and need to be joined. is brazing or using silver solder a good option here? what am i going to need to buy?
thank you

Can you say more about the application? Obviously you need to worry about corrosion with those two different metals. Looking around the web, it looks like an option is to use galvanized rivets or bolts and a spacer between the two pieces...
 
no it has to be welded
it's a piece that i am trying to attach to the bar clamp. let me see what i can do as far as pictures.
 
do you see this?

pica.jpg
 
join metal and metal (steel to aluminum)

now i want a different grip for it like this, or a different caul

2clamp.jpg
 
Make it out of aluminum (or steel, whichever the main clamp is made of) and TIG it
 
Travis_King said:
Make it out of aluminum (or steel, whichever the main clamp is made of) and TIG it

well i don't have a welder, dude. i can buy a Brazing Kit. $30.
i wanted to know if that could do.
 
Brazing steel is pretty easy. Brazing aluminum is a mysterious art for someone who has never done it. But if you have a desire to learn, you can get good information from your welding supplier, or search the web. The trick is to match the right materials, rod material, and temperatures. You may also need to heat treat afterwards.

But for something like this, it is hardly worth the effort unless you are looking for a learning exercise that is likely to include several iterations, especially since you don't know which alloy you are dealing with.

I would use epoxy backed up with mechanical fasteners.

Edit: you can weld aluminum to steel, but that is far beyond the scope of your project. I've seen it done on rare occasions via friction inertial welding.
 
Last edited:
  • #10
Pkruse said:
Brazing steel is pretty easy. Brazing aluminum is a mysterious art for someone who has never done it. But if you have a desire to learn, you can get good information from your welding supplier, or search the web. The trick is to match the right materials, rod material, and temperatures. You may also need to heat treat afterwards.

But for something like this, it is hardly worth the effort unless you are looking for a learning exercise that is likely to include several iterations, especially since you don't know which alloy you are dealing with.

I would use epoxy backed up with mechanical fasteners.

Edit: you can weld aluminum to steel, but that is far beyond the scope of your project. I've seen it done on rare occasions via friction inertial welding.
right
like i don't have a garage or space to start welding lol
and again i am guessing it's aluminum. it might be a different metal.
 
  • #11


they're actually zinc. i was way off-base.
so zinc to steel? weldable? can they be brazed possibly? what do you think?
 
  • #12
The boiling point of zinc is below steel's melting point. Are you sure they are fully zinc, or zinc-coated? Also Zinc contains volatiles that are released when burned and are pretty hazardous. You aren't going to get a good connection between these two materials.

My suggestion (though I know you don't have access to a welder) would be to weld threaded rod onto locations on the clamp, drill holes in the zinc piece, and then bolt.

As Pkruse suggested, epoxy might be your friend for this one. I'd drill some inserts to fit the threaded rod into, epoxy them into place and go from there.
 
  • #13


stinkingbowel said:
they're actually zinc...
Are you certain? I would bet on them being cast-iron.

I also recommend a bolt-on solution. Without the proper equipment and experience, attempting to weld or braze dissimilar metals is just going to give you headaches.
 
  • #14


pantaz said:
is just going to give you headaches.

Literally...

I just wanted to re-stress the point that burning zinc releases toxic fumes.
 
  • #15
i am certain.

pantaz said:
Are you certain? I would bet on them being cast-iron.

I also recommend a bolt-on solution. Without the proper equipment and experience, attempting to weld or braze dissimilar metals is just going to give you headaches.

they're cast and they have different finishes as in they're finished with either brass, pewter dark bronze or satin nickel.
 
  • #16


Travis_King said:
Literally...

I just wanted to re-stress the point that burning zinc releases toxic fumes.

so would you still go with epoxy that is a LePage Epoxy Steel as your #1 method?
 
  • #17
The epoxy will be more effective if you heavily scuff up the surfaces you want to join. Epoxy also works best with a fairly thick glue line, so I would not clamp them together too tightly. Tape can usually provide enough clamping force.
 

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