"Dimi Shahbaz" wrote in message
...
As far as thickness, I think that's a problem. I want to use regular
commercial aluminum foil, so 0.2 mm thickness. The diameter of the
mesh will be 3", the foil will extend past that a few inches. If it
can be made in the thousands, that would be ideal, and preferably at a
low cost. Non-corrosive metals other than aluminum would be fine as
well, if the process is easier.

Thanks again

If we're voting here, I generally agree with Ned. Any kind of metal joining
(soldering, brazing, etc.) is extremely difficult with aluminum foil,
although I have soldered it with success, after many attempts. The point
contact, however, would make that a problem.

Epoxies and silicone adhesives can take a fair amount of heat, as others
have reported. Getting a strong bond to aluminum foil is, again, a problem.
Unless you use special techniques to prepare the aluminum, you will be
bonding to the surface layer of aluminum oxide, not the aluminum itself.

That's generally a weak bond. But you can't apply much load to aluminum foil
anyway, so just gluing it may work. Although I favor epoxies for most
bonding, and silicone is not a great adhesive, the silicone will be more
compliant and it may do a better job in this case.

If it were me I'd try the silicone adhesive as a test and see if it's
sufficient. If it is, it's probably the easiest and cheapest to apply.

--
Ed Huntress