We engineer structural metal bonding epoxy systems that replace welding, riveting, and mechanical fastening without thermal distortion, stress risers, or galvanic corrosion risk.
Standard epoxy formulations do not perform equally across all metal substrates. Our high-strength industrial epoxy systems are engineered substrate-first, with surface preparation protocols and formulation chemistry matched to the specific alloy, oxide layer, and service environment of each metal.
Welding solves a joining problem while creating several others: heat-affected zone degradation in aluminium alloys, distortion in thin sheet assemblies, and stress concentration at every weld toe. Our structural bonding adhesive systems eliminate these failure modes by distributing load continuously across the full bond area rather than concentrating it at discrete points.
Our applications engineers match metal bonding formulations to your substrate, joint geometry, and service environment.
Bond strength in metal assemblies is determined more by surface preparation than by adhesive formulation. Every metal bonding adhesive recommendation made by Kohesi Bond includes a substrate-specific preparation protocol verified to raise surface energy above 40 mJ/m² before adhesive application.
Contamination from machining oils, fingerprints, and mould release agents reduces surface energy below the threshold for reliable adhesion. The correct sequence is:
Chemical degreasing alone is sufficient for low-stress secondary bonding. For structural joints carrying cyclic or peel loads, mechanical abrasion or grit blasting is required after degreasing.
Mechanical surface activation removes the weak native oxide layer and increases surface roughness to improve mechanical interlocking at the bond line. Key parameters:
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Spot welding concentrates load at discrete weld nuggets, creating stress concentration factors of 2 to 4 at each weld site that drive fatigue cracking under cyclic load. Our metal bonding epoxy systems distribute that same load continuously across the bond area, reducing peak stress and extending fatigue life by 5 to 10 times on equivalent thin sheet assemblies. Spot welding also distorts thin sheets through localised heat input; adhesive bonding introduces no thermal load to the assembly.
Our structural bonding adhesive layer physically separates the two metal surfaces, eliminating the ionic contact that drives galvanic corrosion in the presence of moisture or electrolyte. The bond line also seals the interface against fluid ingress, removing the electrolytic pathway required for galvanic cell activity. In marine and high-humidity environments, this barrier function can double the corrosion-free service life of a dissimilar metal joint compared to mechanically fastened alternatives.
For aluminium, phosphoric acid anodise followed by epoxy primer delivers the most durable bond, retaining above 80% of dry lap shear after 1,000 hours of humidity exposure. For steel and titanium, grit blasting to Ra 3 to 6 µm followed by a silane coupling agent provides equivalent durability. Our high-strength industrial epoxy recommendations always include the matched surface preparation protocol because the adhesive performance is only as good as the surface it bonds to.