When planning a project, the way you put together materials is just as important as the materials themselves. Luckily, aluminium plates offer a lot of versatility when it comes to assembly – but which aluminium plate assembly method is best?
The experts at MG Metals have years of experience working with aluminium, including plates, sheets, extrusions, and more. In this guide, we’ll explore some popular methods for joining aluminium plates, breaking down the pros and cons of each so you can choose the perfect technique for your project.
Mechanical Fasteners
Riveting
Riveting involves mechanically interlocking two or more pieces of aluminium together with a rivet. It creates a strong hold, but unlike screws or bolts, it can’t be easily undone. It also leaves permanent marks on the surface.
Screws and Bolts
Screws and bolts also offer a secure hold, but they’re easier to take apart when needed. The threads and head styles come in all shapes and sizes, so you can find the perfect fit for any thickness of aluminium. On the downside, they can leave permanent marks just like rivets, and you need to be careful to consider the galvanic compatibility between the aluminium and the fastener material to avoid corrosion. The screw and bolt heads can also be bulky and stick out from the aluminium surface.
Welding
Welding uses high heat to melt aluminium plates together before allowing them to cool. In some cases, a filler material is added to create a pool of molten metal that cools to form a strong bond.
Welding is the strongest and most permanent assembly method, but it requires specialised equipment and can cause distortion in the plates.
There are three main types of welding you can use:
MIG (Metal Inert Gas) Welding
MIG is a versatile arc welding process that uses a consumable electrode to create a weld pool. It’s fast and cost-effective, but requires a skilled welder.
TIG (Tungsten Inert Gas) Welding
TIG offers a more precise weld using a non-consumable tungsten electrode. It produces clean welds, but requires more operator skill than MIG welding.
Friction Stir Welding (FSW)
FSW is a solid-state joining technique that uses a rotating tool to generate frictional heat, forging the aluminium parts together without melting them. It creates a strong bond and minimises distortion, but requires more operator skill than MIG and TIG welding and access to both sides of the workpiece for the rotating tool.
Adhesive Bonding
Adhesive bonding involves using adhesives like epoxy, acrylic, and polyurethane to attach aluminium plates. It’s a quick and easy option for simple joints and works well in applications where heat is undesirable or for joining dissimilar materials. However, it’s not suitable for high-stress applications, and the bond’s strength and durability depend heavily on the type of adhesive and surface preparation.
Clinching
Clinching, also known as press-joining, is a technique used to fasten aluminium plates together without rivets, screws, or pre-drilled holes. It creates a permanent button-like interlock between the sheets using a special clinching tool.
The process is very quick, often taking less than a second, and doesn’t require additional fasteners. However, the joints are not as strong as other assembly methods.
Which Assembly Method Should You Use for Your Aluminium Plates?
While each method has its strengths, the best choice for your project depends on a few key factors. Here are some questions to help you decide:
1. How much weight will the assembly need to support?
Welding is generally the strongest method for high weight support. Riveting, bolting, or screwing can be good options for medium weight requirements, while adhesive bonding is only suitable for low weights.
2. Are the plates overlapping, butting together at a corner, or in some other configuration?
Welding, riveting, screwing/bolting, and adhesive bonding are all viable methods for joining overlapping plates. The best option depends on your weight, stiffness, and finish requirements.
On the other hand, welding and clinching are the most convenient methods for joining plates at a corner. Clinching is particularly good for sheet metal applications where a smooth finish is needed.
3. How thick are the plates?
Adhesives, clinching, and riveting are good options for thin plates. Welding can also be used, but care must be taken to avoid burning through the material. For thick plates, welding, screwing/bolting, and riveting are all suitable. The best choice depends on the weight, stiffness, and finish requirements.
4. Does the finish need to be smooth for aesthetic reasons or to prevent corrosion?
Adhesives and clinching can provide a smooth finish. Welding can also be used, but the weld bead will need to be ground smooth if a cosmetic finish is required. Screw heads and rivets can protrude from the surface, so they may not be ideal for applications requiring a perfectly smooth finish.
5. Are you making a one-off prototype or a large production run?
Welding, clinching, and screwing/bolting are typically the most cost-effective methods for large production runs.
Buy Premium-Quality Aluminium Plates From MG Metals
No matter how you choose to assemble your project, there’s one crucial ingredient: the right aluminium plates. And you’ve come to the perfect place to find them!
- We offer a huge selection of aluminium plates, from thin sheets (6mm) all the way up to thick slabs (152.4mm). All come cut to a tolerance of just 0 to +2 mm for a perfect fit.
- We stock popular grades like 5083, 6082, and 7075 for aluminium plates, and 5000 grade for tooling plates.
- We also offer finishing options like anodising and powder coating.
- Most orders are sent out within 3-5 working days, and they’ll be with you the very next working day thanks to our speedy 24-hour courier service.
Ready to bring your vision to life? Get a free quote online or give us a call on 01794 521070 today!