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Metal finishing Q&As since 1989

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Aluminum Bonding

I'd like to build my own recumbent bike with electric assist. Is using bonded aluminum an option that I could take to make the framework without welding?

David McKnight
- Austin, Texas
2002

In theory yes. Lots of aerospace structures are bonded aluminium structures. In practise just look at the market place. There are no bonded structure bikes out there I know of. You will almost definitely have to redesign the frame to account for the joints. Adhesives are great in tension, peel and shear forces can be very different. Many thermoset resins are fairly brittle. The strongest adhesives need good surface preparation. Minimum would be degrease and conversion coating for any sort of durability. Many structures are bonded and rivetted. If you are serious think about this as a belt and braces approach.

If you are willing to put the hours in yes it is very possible. If you just want to put adhesives where you currently have welds you will almost definitely end up with a failure, potentialy dangerous.

Ciaron Murphy
- Great Britain
2002

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