Fusing

Fusing is a general term for joining two or more materials into a single piece through the application of heat, pressure, or chemical means. The specific technology varies by material: some processes melt the base material, others rely on a melted filler, and some create bonds by softening surfaces and allowing diffusion. Fusing is used across metalworking, glass, textiles, and plastics, among other fields.

In metalworking, common fusing methods include welding, brazing, and soldering. Welding generally melts the base metals to form a homogeneous joint, sometimes with a separate filler. Brazing and soldering rely on a molten filler metal that bonds through capillary action, with the base pieces remaining solid. Other approaches such as friction welding or ultrasonic welding use heat and pressure to join parts without significant filler.

Glass fusing is a specialized process where pieces of glass are heated in a kiln until they fuse at their surfaces, creating a continuous piece that is often decorative. In textiles, fusing typically refers to the use of fusible interlinings or adhesives that bond fabric to fabric when heat and pressure are applied. In plastics, plastic welding applies heat, friction, or solvent bonding to fuse plastic components.

Key considerations include material compatibility, joint design, temperature control, and processing time, as well as safety and environmental factors. Fusing can produce strong bonds but may introduce residual stresses, distortion, or susceptibility to environmental factors if not properly controlled. The choice of method depends on materials, required joint strength, and application conditions.