Body Panel Adhesive VS Welding [Guide & Suggestions]

Perfect attachment for the body parts is too important for security. Body panel adhesive and welding, both can do this job with great delight? Body panel adhesive vs welding is crucial to explore here with critical applications and advantages.

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But, have you ever thought, which will suit you more?

Actually, no one can blindly tell the most advantageous one. It is a matter of good experience and deep knowledge.

Both of these techniques are too different and fit for a unique purpose.

To get the necessary knowledge…

Explore this quick post that is a good collection of advantages, disadvantages, applications, and general discussion.

Body Panel Adhesive VS Welding

Body Panel Adhesive

A body panel adhesive is the joining of the same or different metals with each other with the help of glue. This bonding needs curing time. So, it results in a flexible and durable bond between the joining metals.

You must be thinking of the best adhesive on the spot!

Cyanoacrylate or super glue is one of the very famous body panel adhesives. It is strong but heat, moisture, humidity, and definitely, time can disturb it.

These adhesives are neutral to the galvanized surfaces. So, distortion and discolouration do not occur. Aerospace, automotive, and structural construction say welcome to the body panel adhesive.

Application of body panel adhesive

The body panel adhesive is good in thin metals and has the following advantages;

  • In automotive assembly, the adhesive not only keeps the weight at a minimum but also boosts the construction process. Moreover, the chances of corrosion have diminished.
  • Pre-mature material in aircraft stays fit with adhesives. Therefore, these do not demand, nuts, bolts, drills, and other fasteners.
  • In constructing the buildings, the adhesive works as a good choice to stick wood, glass, and metals together.
  • Exterior cladding reduces the stress riser with the help of adhesive.
  • Body panel adhesive is cost-effective and does not increase the weight of the metal.

Advantages of body panel adhesive

  • This glueing process does not increase the weight of the metal.
  • The chances of noise and vibration are minimal.
  • Limited stress in the bonding zone.
  • Comes with enhanced fatigue strength.
  • Glueing acts as permanent bonding.
  • Similarly, you will need minimum labour work.

Disadvantages of body panel adhesive

  • It needs a cure time to settle the glue.
  • The life of glue is limited.


Welding is the joining of two metals with the help of intense heat. In conclusion, these metals fuse together after being melted and a strong bond is formed.

For instance, the same metals have the same melting time, therefore it is favourable for the same metals.

Laser welding is needed for automotive components such as the engine, solenoids, fuel injectors, fuel systems, and more.


Pre-machined elements can be welded together while producing reduced distortion. In contrast, the thin metal does don’t increase its weight with this trick.

However, the resistance spot welding has replaced the laser welding that entertains car roof and side panels.

Applications of welding

Like body panel adhesive, welding also comes with a unique application. These are;

  • The structural performance of the vehicles has been enhanced with laser welding. In this way, it indexes the thickness of the metal in question.
  • Heat leaves less effect with reduced distortion followed by speedy production.
  • Multi-layer joints increase flexibility.

You can use the best tig welder for aluminum for great performance.

Advantages of welding

  • You will need lesser time for welding.
  • Welding is a quick process with instant results.
  • Welding produces a strong and durable bond.
  • High temperature does not affect the bonding
  • Bonding is permanent

Disadvantages of welding

  • Dissimilar metals melt at different times due to unique melting points. This fact makes welding a bit complicated.
  • Welding increases, the chances of corrosion.
  • It needs dressing in some cases.
  • Thin metals may suffer from discolouring and distortion after welding.

Final Words

Body panel adhesive vs welding has been discussed as both have similar results at the end, the binding. Every type has unique applications and advantages. Which would work best, depending upon your need.


You must use adhesive in order to join the thin metals. On the other hand, welding can fit well with thicker metals. With respect to cost, adhesive seems good as it does not need a power source. Whereas, welding needs a power supply that may be changed according to welder strength and power.

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