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Thomas, there are two ways that I have used to merge .SAV files. Either way, you'll want to start by making sure that all bus numbers are unique. Otherwise, you may create some spurious connections. If there is some overlap, perhaps you could add a digit to the start of all the bus numbers in each file, so that buses from one file start with a 1, and buses from the other file start with a 2. Areas, owners and zones could cause similar issues.

Method 1 (Manual approach): In PSSE, click the "Select all buses" option to ensure you're seeing everything. Next, go through each tab of the network data, and copy and paste it into your other file. I usually record myself doing this so that I have a script for it later. This is probably similar to your .RAW method.

Method 2 (GridCompare): GridCompare is free software developed by Whit, that is designed to show the differences between two cases and generate a python script to transform one case into the other. So, if you have one case post-augmentation, and one case pre-augmentation, it will build a python script for the augmentation. Now, what you're doing is different to this, but you could still make use of it. The python script that is generated by GridCompare is split into "Removed Elements" and "Added elements". All you need to do is delete the "Removed Elements" section of code, and you'll be left with a script that simply adds one case to the other. You could even edit the GridCompare code to deliver exactly what you're asking without the post processing, if you're keen on it.