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I'm no expert on sheet metal fabrication and hopefully someone will come along with a more confident one, but in general I would expect that soldering/brazing is the correct answer. (solder in reality would be hard to do, it running all over the place or being lumpy.) From what I have seen of soldering large metal parts (with a torch, not an iron), with ...


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For very narrow gauge, as in the sheet metal used for the waveguide in a microwave oven I think it's a process involving a roller disc inside the waveguide making spot welds at the closest interval possible and doing multiple passes until it's continuous. People reviewing TIG welders on YouTube routinely weld razor blades together. Any thin steel that's ...


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For really fine control of soldering, use a soldering gun as a resistance welder. Just cut off the end of the heating tip, so that instead of a loop you have two big copper wires coming out of the gun. Press them onto either side of the joint and pull the trigger. The current passing through the metal will quickly heat it to the point where it will melt the ...


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