Aluminum profile is widely used in various industries due to its high strength-to-weight ratio, corrosion resistance, and workability. However, to maximize the full potential of aluminum profile, it is important to properly join different sections together. Here are some of the most common techniques used for joining aluminum profile:


Welding is one of the strongest and most durable methods for joining Aluminum Profile. Gas metal arc welding (GMAW), gas tungsten arc welding (GTAW), and metal inert gas (MIG) welding allow sections to be permanently fused together. Friction stir welding creates uniform welds of excellent quality without the heat effects of fusion welding. Welding provides high structural integrity critical for load-bearing applications.


Mechanical Fastening
Screws, bolts, and nuts are versatile fasteners that allow for easy joining and disassembly if needed. Self-tapping screws grip aluminum profile securely without predrilled holes. To prevent corrosion, fasteners are often cadmium or zinc plated.


Adhesive Bonding
Epoxy structural adhesives form durable, vibration-resistant bonds ideally suited for types of aluminium profiles applications with complex geometries. Film adhesives can handle wider temperature ranges. Adhesives distribute stress loads effectively across the bond line.


Pop rivets and blind rivets provide a fast assembly solution, especially for thinner gauges. Combination rivets join different thicknesses. Solid shank rivets withstand high shear, tensile and fatigue stresses.


Adhesive bonding is a newer joining method that utilizes high-performance structural liquid adhesives such as epoxy resins or acrylic acids. After heat curing, it can form a highly strong permanent bond. This method has low shape and size requirements for the types of aluminium profiles, is easy to operate, seamless by nature, and has good impact resistance.


Clinching is a mechanical connection technique that deforms one material over the edge of another under pressure without any additional fasteners. This provides a watertight, vibration-resistant bond. Clinching can be done using standard metal stamping equipment and is cost-effective for large volume production.


Compression riveting joins multiple materials simultaneously through the use of a tug nut on the backside. The bonding mechanism involves compressing the rivet body to flare the tails securely under the base metal. It provides accessibility to both sides and an excellent visual presentation.


Friction plug welding utilizes a rotating shouldered pin or sleeve that generates heat through friction to plasticize and displace the aluminum as it is inserted. This self-piercing process works on dissimilar materials and leaves a neat weld on the frontside for applications like automotive body panels.


There are also innovative methods like flow drilling that combines drilling and tapping screws in one step to make a form-fitting connection minimizing fastener exposure for a flush profile assembly. The technique chosen depends on the specific project requirements.