Sika POWER TO METAL: Bonding as a Complement to Welding in Metallurgy

Structural bonding is revolutionising metal assembly. As a complement to welding, structural bonding reduces rework, preserves the aesthetics of parts, and improves stress distribution.

The Sika POWER TO METAL range integrates into existing processes to boost performance, safety, and productivity, from HVAC to special machinery, including the manufacture of cabinets and chassis.

 

What is Sika POWER TO METAL?

 

Sika POWER TO METAL brings together structural bonding solutions for metallic substrates (steel, stainless steel, aluminium, and alloys) designed for industrial assembly.

They allow for hybrid assembly: welding is used where necessary (rigidification, metallic continuity, local high-temperature resistance), and bonding is used where possible (homogenous stress distribution, sealing, aesthetics, dissimilar assemblies). The objective is twofold: to secure quality and streamline production.

 

Why Choose Hybrid Assembly (Welding + Bonding)?

 

Structural bonding complements welding in four major areas:

  • Dimensional Quality & Aesthetics: No thermal input → no distortion, limited weld-print, regular joint.
  • Mechanical Durability: Uniform stress distribution, reduction of crack initiation, better fatigue resistance on large bearing surfaces.
  • Materials: Metal-to-metal and metal-to-non-metal assembly (paints, composites, compatible plastics) with integrated sealing function.
  • Health, Safety, Resources: Reduced exposure to fumes/heat, lower dependence on scarce welders, simplification of rework.

Points of Attention: Surface preparation, control of open time/curing, assembly conditions (Temperature, Humidity), and process validation (adapted control plans).

 

Application Fields

 

  • Mechanical Engineering & Automation: Bonding stabilises frames and stiffens casings and covers without thermal distortion. Cable trays and cladding gain in flatness and aesthetics while limiting rework.
  • Metal Processing: For cabinets, enclosures, tanks, and boilers, the technology brings sealing continuity and better fatigue resistance over long joint lengths. Welding rework decreases, and finishes are simplified.
  • HVAC: Hybrid assembly facilitates the integration of unit casings, frames, and doors. Bonding dampens vibrations, reduces radiated noise, and preserves surface finishes before painting or powder coating.
  • Vehicles & Equipment: Welding and bonding are combined for sub-frames, cabins, and cladding. Loads are distributed over the surface, the assembly of dissimilar materials is secured, and the visual finish remains constant from one series to another.

Key Sectors:

  • Mechanical Engineering & Automation

  • Metal Processing
  • HVAC
  • Vehicles & Equipment

 

Sectoral Use Cases

 

1) Manufacturing of Cabinets and Enclosures: By bonding panels onto frames, flatness and appearance are maintained without deformations linked to welding. Rework times (grinding, straightening, painting) drop, and capacity increases with constant staffing.

2) Tanks and HVAC Casings: Bonding plays a dual role of assembly and sealing. Vibrations are dampened, noise decreases, and joint integrity is improved over time thanks to the bearing surface of the bead.

 

Comparison: Structural Bonding vs Welding (Summary)

 

Criterion

Structural Bonding

Welding

Thermal Input

None → No distortion

High → Risk of warping

Stress Distribution

Homogenous over the surface

Concentrated at the beads

Materials

Metal-metal and dissimilar

Compatible metal only

Aesthetics

Clean joint, burr-free

Traces, rework/grinding needed

Sealing

Integratable into the joint

Addition of operations

Skills

Versatile

Qualified welders required

Service Temperature

Limited depending on chemistry

Excellent locally

Key Takeaway: Welding remains essential for metallic continuity and high-temperature zones; bonding excels at distributing loads, preserving aesthetics, and integrating sealing. Hybrid assembly combines the best of both.

 

Choosing Your Reference: Selection Guide

 

To select the most suitable Sika POWER TO METAL solution, consider:

  • Substrate and Surface Condition: Steel/stainless/aluminium (raw, galvanised, painted); preparation level (degreasing, abrasion, potential primer).
  • Assembly Kinematics: Viscosity/thixotropy (vertical beads), open time, repositionability, setting (rapid handling vs slow polymerisation).
  • Gap Filling: Part flatness, need for flush adjustment.
  • In-Service Constraints: Vibrations/fatigue, temperature and agents (humidity, fluids), differential expansion (metals/paints).
  • Downstream Process: Painting/powder coating, thermal treatments, cleaning.

 

ACROM x Sika Solutions

 

ACROM is an official Sika distributor, and we support the definition of the hybrid process (pre-treatments, tooling, control). We offer the Sika POWER TO METAL range and adapted auxiliaries (primers, application accessories, dispenser guns).

Our teams guide you towards references compliant with your production rates (manual, semi-auto, robotic) and your HSE constraints.

Need technical framing? Our specialists evaluate your assemblies from drawings, define samples, and propose an adapted testing protocol. ACROM also supports you in choosing dispenser guns and mixers for product application.

 

Best Usage Practices

 

Surface preparation largely conditions the joint strength: it is often half the success of a structural bond.

  • Controlled Preparation: Metal-compatible degreasing, controlled abrasion (grit/pressure), dust removal, primer if required by aluminium.
  • Reproducible Application: Dimensioned beads (width/thickness), documented assembly pressure and holding time.
  • In-Line Quality: Jigs/spacers for gap control, monitoring of open time/Temp/RH conditions, batch/reference recording.

 

Safety & Compliance

 

Implement HSE evaluation and operator training: SDS reading, adapted PPE, workstation ventilation, waste management. Verify process compatibility (painting, baking) and normative requirements of your markets (transport, construction, pressure equipment) in liaison with our teams.

 

FAQ

 

Does bonding replace welding?

No. It complements welding: welding is reserved for zones where metallic continuity or high temperature are indispensable, and bonding is used elsewhere to distribute loads and gain in aesthetics/sealing.

Which surfaces are compatible?

Steel, stainless steel, aluminium/alloys. Preparation (degreasing, abrasion, primer) conditions the hold. Assemblies with paints and certain plastics are possible after testing.

How to control open time?

By marking out the assembly window (temperature/humidity), organising workflows (pre-assembly, jigs), and choosing kinetics adapted to your speed.

Can we paint after bonding?

Yes, under conditions: respect curing times, baking temperatures, and use compatible systems.

What quality control?

Batch/parameter traceability, destructive testing on specimens, dimensional and visual checks.

 

Upcoming Sika Webinars

 

  • Thursday 6 November 2025, 11:00–11:45 (CET)
  • Tuesday 20 January 2026, 11:00–11:45 (CET)

Program: Benefits of bonding + welding, feedback, methods to simplify production, Q&A session with Sika experts. Free online registration.

 

About ACROM

 

As a specialist in industrial adhesives, ACROM helps you dimension the right assembly process: product choice, preparation, parameters, control.

Contact our teams for an assembly diagnosis or a material test: feasibility study, protocol, and ramp-up support.