How to Remove Rust from Metal？

What is Rust?

Rust is a form of corrosion that occurs on metals that contain ‘iron’ and its alloys like ‘steel’. This occurs as a result of the oxidation process between iron, oxygen and water. When iron comes into contact with oxygen and water vapor in the atmosphere, it reacts and forms iron (III) oxide, which we commonly call ‘rust’.

Several factors lead to the formation of rust. Primarily, the environment where the metal is stored can have a high effect on the process of rusting. In other words, the higher the temperature, the faster the rusting process. This is because water and oxygen molecules are more active in higher temperatures which enables them to react easily with iron molecules. Moreover, chemicals like salt can also accelerate the rusting process. Therefore, rusting occurs at high rates in coastal areas due to the high presence of salt in the air. Furthermore, acids too can increase rusting as acids break down the oxide layer on the surface of the metals which leaves them exposed to oxygen and water.

Therefore, rust becomes a serious problem in humid environments, wet climates and coastal areas, where the temperature, moisture and salt in the air are excessively present. This may lead to excessive damage and wastage of iron.

Iron is used in various industries due to its irreplaceable benefits, especially in relevance to its strength and durability. However, rusting of iron might prove to be a serious problem as it can reduce the beneficial characteristics of iron. This can eventually cause the iron structures to lose strength and lose the ability to be used in any activities.

Some effects caused by rust are:

• Structural integrity- Rust on metal surfaces weakens the metal structures, which compromises the durability of the metal structure as a whole. This occurs as a result of a loss of material from the metal surface. Furthermore, rusting at joints and other local areas of structures can lead to faster deterioration of the metal structure.

• Increasing costs due to reduced lifespan- This is one of the most significant disadvantages caused by rust. Due to the rusting process, the degradation of metal can increase, which eventually leads to the failure of the metal structure, even at a premature stage. Industries which use metal structures should take apt measures to ensure proper protection of metals to reduce the effects of rust as possible. Besides, failure of these structures can lead to an increase in costs for the industries as they might have to replace the entire structure due to degradation.

• Damage to aesthetic appeal- Due to rusting, the original appearance of the metal structures can appear differently. The reddish-brown change in appearance can look ominous, thereby decreasing the visual appeal of these surfaces. In a commercial space, rust on the metals can affect the first impression of the business on guests.

Regular rust removal helps to battle against these effects, by improving the appearance of surfaces and maintaining the integrity of the object. What’s more, is that it can also help to increase the lifespan of metal structures which can save the industry from going for cost wastage due to replacements.

While there are several ways to prevent rusting from happening, if the problem has already been caused, here are some ways it can be handled.

Methods for Removing Rust from Metal

1. Mechanical Methods

Mechanical rust removal includes methods like using sandpapers, wire brushes and grinders. Using these is best suitable for surfaces with light to moderate rusting. Further, it is effective for small areas of rust and objects that can be held in the hands. Although it is a simple and inexpensive method, it can be time-consuming and physically tiring. Moreover, this method can also remove some of the surface material, which can prove unsuitable when used on sealing surfaces.

2. Chemical Methods

In addition to mechanical methods, chemical methods can also be used based on the severity of rusting. Chemicals like white vinegar, baking soda, lime and other homemade solutions can prove to be effective chemicals in removing rust domestically and inexpensively.

As it contains acetic acid, vinegar is a strong chemical that can be used to dissolve rust. In fact, Vinegar is one of the household items which can be used for almost any purpose when it comes to cleaning.

Baking soda is another similar effective chemical that can remove rust. Its grittiness and abrasiveness give the scrubbing power that is required to clean away from metal surfaces. It also reacts with acids like vinegar which helps in removing rust from metal surfaces effectively.

Another method of removing rust from metal surfaces is using commercial rust-removing chemicals. Due to the presence of strong chemicals in these commercial products, they can be more effective than other solutions that can be prepared in the household. However, when using such commercial chemicals, it is important that the person takes necessary safety measures as it can cause physical harm and accidents.

3. Electrolytic Rust Removal

This is another simple safe and sheep but effective way of removing rust from any metal surface. In this method, rust can be removed without using chemicals. An electronic charge is used to remove rust which can later be scrubbed using soap and water. The below things are needed to remove rust using electrolysis.

• A cathode and anode
• Sandpaper
• Battery charger
• Copper wire
• Plastic or glass container
• Wire brush
• Wire cutters
• Washing soda
• Steel wool

4. Post-Rust Removal Care

Rust can be prevented or reduced from forming on metal surfaces through various methods. Moreover, after rust has been removed from a surface, it is imperative to ensure there is regular maintenance. Some ways of preventing rust formation are,

• Painting or coating a metal surface to prevent direct contact with air.
• Galvanization, where zinc is applied on the surface as a protective layer.
• Using a rust-resistant metal like stainless steel or aluminum.