Thermal joining, which includes welding, soldering, and brazing, is only effective on homogeneous metal substrates with similar melting points. Thermal methods of assembly are very difficult to disassemble and can result in aesthetic concerns such as distortion and discoloration. By grinding or sanding down the substrate to minimize the metal bump or discoloration, and painting over the problem area, if necessary, manufacturers can often solve these aesthetic concerns. Distortion, which is caused by uneven heating and cooling of the part, is more difficult to repair.
Welding, while typically less visible than fastening, can distort or heat warp the metal and weaken the alloys. It can burn off galvanized metal’s corrosion protection. It often requires finishing once joined.
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