Material guide
Gluing Aluminium
Bare or mill-finish aluminium as found in extrusion, sheet, tube and castings.
Also called alloy, ally, aluminum.
How Aluminium behaves when you bond it
Aluminium grows a fresh oxide layer within seconds of being abraded, so what an adhesive actually sticks to is that oxide rather than the metal. Bonding promptly after abrading and degreasing makes a measurable difference.
Bare aluminium is a high-energy metal covered immediately by a thin oxide. Adhesive can bond strongly to that oxide, but contamination or a weak hydrated oxide can limit environmental durability even when initial strength is high.
Material properties
- Surface energy
- High, which helps adhesion
- Porosity
- Non-porous
- Rigidity
- Rigid
- Maximum service temperature
- 150C
- Normally needs abrading
- Yes
- Normally needs a primer
- No
- Recommended abrasive grit
- 80 grit (WEST SYSTEM epoxy preparation for aluminium.) Manufacturer verified
Surface preparation
Degrease before abrading so oil is not spread. For WEST SYSTEM epoxy, dry-sand aluminium with 80-grit paper, remove residue and apply promptly. Structural production work may require a qualified etch or conversion treatment; do not improvise hazardous industrial etches from a general guide.
Which adhesives work on Aluminium
Excellent
Structural acrylic
Structural acrylic is rated excellent for this material as an application-level assessment, not as a blanket manufacturer claim. The prepared surface must be sound and consistently keyed where the finish permits. Suitability still depends on the other substrate, joint design and service environment.
Abrade the surface first.
Excellent
Two-part epoxy
Two-part epoxy is rated excellent for this material as an application-level assessment, not as a blanket manufacturer claim. The prepared surface must be sound and consistently keyed where the finish permits. Suitability still depends on the other substrate, joint design and service environment.
Abrade the surface first.
Good
Acrylic foam tape, VHB type
Acrylic foam tape, VHB type is rated good for this material as an application-level assessment, not as a blanket manufacturer claim. The prepared surface must be sound and consistently keyed where the finish permits. Suitability still depends on the other substrate, joint design and service environment.
Abrade the surface first.
Bonding Aluminium to something else
Aluminium to XPS foam board
Aluminium to Polyurethane foam
Aluminium to EPS (polystyrene foam)
Resin 3D print to Aluminium
Aluminium to Powder coated metal
Aluminium to Plywood
Aluminium to Pine
Aluminium to Oak
Aluminium to MDF
Aluminium to Concrete
GRP / fibreglass to Aluminium
Aluminium to Aluminium
Last reviewed 8 October 2026.