Weld less, produce more.

New Paths to Profitability

The long-predicted shortage of skilled workers is here, with the lack of trained welders alone numbering in the millions globally. For metal fabricators of commercial and off-highway vehicles and equipment, this too often means turning down new business and putting the brakes on profitable growth, or making costly investments in robotic welding equipment. Fortunately, Sika’s long-term efforts to improve productivity, material efficiency and mechanical durability through  adhesive bonding are opening new paths to profitability.

The Hard Facts on Durability

Structural adhesives display a more even stress distribution than weld lines, which are prone to cracking in highly dynamic environments. In fact, the service life of an adhesive bond can outlast both mechanical fasteners and welds by a factor of three or four due to the ability to better absorb impacts, vibrations and movements. Put simply, fewer stress peaks mean more durable joints, provided a few basic design principles are applied. 

Preserving Material Integrity

In a welded joint, the high-heat input of the welding process alters the material structure, often leading to the formation of heat-affected zones and grain boundary precipitates. These undesirable microstructures are common sources of localized corrosion attacks, and can be completely avoided by adhesive bonding, which preserves the material’s original metallurgical properties. The result is a bonded assembly that is resistant to harsh environments and corrosion, which can substantially prolong the service life of the assembled parts.

Say Goodbye to Grinding and Polishing

Above all, the major driver for developing metal-to-metal bonding solutions lies in its cost advantages. In particular, valuable labor time can be saved by eliminating post-weld treatment work like sanding, grinding and polishing. For a single assembly process, the speed and repeatability of bonding can contribute to as much as 70% faster output at up to 80% lower cost.

Combine Materials and Cut Weight

In the drive to cut weight and save resources, today’s fabricators have a nearly limitless range of material technologies at their disposal. The right adhesive solutions open new doors to durable, combinations of steel and aluminum, coated metals, composites and more, making it possible to implement innovative, weight-saving designs while maintaining or improving durability. Sika collaborates every day with innovative design engineers to streamline the joining of metal with metal and other materials based on an extensive portfolio of 1-component heat-curing epoxy and 2-component structural adhesive systems.

Start small. Scale up.

Of course, not all assemblies are suitable for adhesive bonding. Some joint designs simply can’t be changed. Others exceed service life temperatures of 300°C, where most adhesives begin to depolymerize. But in most fabrication and manufacturing environments, a thorough evaluation typically reveals significant opportunities for metal bonding processes and hybrid joining techniques that are both more durable and cost-efficient. As most of Sika’s partners would attest, it pays to start small, scale up and build out your capabilities together.

Quality Design Starts with Quality Data

Because every customer challenge is unique, Sika is heavily invested in the local presence of application engineers and design engineers in more than 100 countries to support the entire customer journey from the initial design phase to final industrialization. Starting with a cost assessment of your designs and processes, we apply a fully data-driven approach to the transition to adhesive bonding. From identifying design issues to expert lab testing, technical process support, implementation, validation and training, we’re with you every step of the way. Together, we can develop the right opportunities to move your business forward.

Discover how Sika’s adhesive bonding solutions can move your business forward.