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Laser Rust Removal for Home-Used Metallic Tools
You might have seen some huge laser cleaning machines used for car rust removal, or so. Actually, with the same principle, lasers in desktop laser engraving machines can perform laser rust removal. If you have a fiber laser marker with rusty keys, memorable coins, or a knife, it is time to "engrave" rust away from your daily metal items.
How Do Metallic Items Get Rusty?
First, we need to understand why things get rusty. At its chemical level, rust occurs when metal is exposed to moisture and oxygen. The chemical reaction that causes rust is a form of corrosion that slowly eats away at the rusted metal surface (Resource: zrcworldwide.com). A wet metallic surface combined with oxygen causes rust. Metallic projects, especially those made of iron, are more prone to rust because iron is high on the metal activity order and is prone to oxidation due to electron loss.
Steps to Laser Rust Removal
To be honest, there's little difference between laser cleaning and laser engraving; you only need to change the power and speed. For removing the rusty part, you'd better use a 50W or above desktop fiber laser engraver, but even a 20W fiber laser engraver can perform laser rust removal.
1. Decide the Work Area: For example, if you would like to deal with a rusty coin, draw a circle in the Lightburn interface and set the parameters, such as 100% power with 500 mm/s (for a 20w fiber laser engraver). You need to fill the circle like the example below, or you may only engrave the edge of the coin.
2. Put a Drop of Water: Due to the thermal principle of fiber laser engraving, a small drop of water may help to lower the heat of the engraving surface. The water will also be vaporized during the engraving process.
3. Firm the Coin: Laser rust removal may take a while, and to prevent the coin from moving, you need to secure it with tools or other materials that don't easily react with the fiber laser.
4. Adjust Parameters: Once you laser engrave the entire surface with the original settings, adjust your parameters based on the engraved result. Increase the power or slow the speed.
3. Firm the Coin: Laser rust removal may take a while, and to prevent the coin from moving, you need to secure it with tools or other materials that don't easily react with the fiber laser.
4. Adjust Parameters: Once you laser engrave the entire surface with the original settings, adjust your parameters based on the engraved result. Increase the power or slow the speed.
Notes
It is worth mentioning that a laser protective cover and laser safety goggles are needed during laser engraving work. Every time after engraving, you can view the engraved surface directly. As mentioned before, desktop laser engravers without a protective cover and laser safety glasses are certified as Class 4 lasers.
Laser Rust Removal, Sandblasting, and Chemical Methods
These three rust removal methods have very different trade-offs. Here is a simplified summary of the pros and cons for each:
Laser Rust Cleaning
Pros: Non-destructive and highly precise—it removes rust without scratching or altering the metal's dimensions (e.g., fine threads). It is also fast, clean, and environmentally friendly, generating minimal waste besides vaporized dust.
Cons: The primary issue is the very high cost (typically $4,000 to over $8,000 for a home-use unit). It also requires strict safety gear (certified goggles) as it operates using dangerous Class 4 laser light.
Related Reading:
Laser Cleaning all you need to know
Sandblasting
(Resource: wbscoatings.com)
Pros: Extremely fast and effective at clearing thick, heavy rust and coatings over large surfaces.
Cons: It is a destructive process that damages the original metal surface, removing material and ruining fine details. It is also loud, messy, and polluting, creating large amounts of dust and abrasive waste.
Chemical Methods
(Resource: yourbestdigs.com)
Pros: Non-destructive to the metal's shape, making it ideal for precision parts like screws and threads. It is also the cheapest option, often using household items.
Cons: It is very slow, requiring long soaking times. It creates chemical waste liquids that need careful disposal. Additionally, failure to completely rinse the metal can lead to secondary corrosion.
How Many Watts Do I Need for Home Laser Cleaning?
20W will be my suggestions, and 50W - 80W maybe the best, for it is only a desktop laser engraver for the home-used. Whatever, I had searched laser rust removal online, and found some machine review celebraties try laser cleaning with 2W IR laser. It's all based on your budget and needs; if you aren't constrained by time, you may try a low-power laser to do the job.
Laser Gun Rust Removal
Some people pay for laser rust removal of their guns; the steps can be followed as above. There are some tips you need to know for this application:
- We recommend using laser rust removal because it can remove the corrosion without damaging the metal beneath. The second-best way is chemical liquid.
- Dismantle the firearm and remove the rust from the corresponding area. This is the most important step because laser engraving is a thermal process that generates high heat to remove the rust. For safety considerations, you must dismantle the gun first!
- Test the settings on a non-critical area or a scrap piece of metal. This helps find the optimal cleaning parameters, ensuring that only the rust is removed without damaging the underlying material.
- Since lasers can easily remove surface coatings, you must avoid direct laser exposure to important markings like serial numbers, manufacturer logos, or any engravings you must keep. Alternatively, you can use very low energy settings for extremely cautious cleaning in those sensitive areas.
While honestly speaking, we do not recommend laser novices attempt this job, especially using laser gun rust removal for machine testing. We prefer to get this job done by professional laser experts only if you are very familiar with laser engraving.
FAQs for Rust Laser Cleaning
Q1: Does laser rust removal really work?
Yes, absolutely. As we illustrate before, laser cleaning is used widely in industrial fields like manufacturing, it moves away the rusty parts without destorying the metal beneath.
Q2: What is the cheapest way to remove rust?
The most cost-effective methods for rust removal typically involve using common household materials, such as white vinegar or a baking soda paste, for chemical soaking or scrubbing. These substances leverage their acidity or mild abrasive properties to dissolve and lift light rust.
Another inexpensive option is to use fine-grit sandpaper or steel wool for manual physical abrasion. However, for any precise or valuable metal item, these home remedies carry the risk of corrosion or scratching the surface. In such cases, it is best to use professional rust removal oils or solvents along with nylon brushes or soft cloths, ensuring the best possible protection for the item while maintaining a balance with cost.
Q3: How long does laser rust remover last?
High-quality industrial fiber laser sources (the most common type used for rust removal) typically have a lifespan of 50,000 to over 100,000 operational hours. We em-smart fiber laser engravers have a lifespan of 100,000 hours with 2-year warranty.
Q4: What kind of laser removes rust?
The dominant laser for rust removal is the Fiber Laser, which operates by laser ablation—using a 1064 nm near-infrared beam that is highly absorbed by the rust (causing it to vaporize or eject) but reflected by the clean metal underneath. Especially pulsed fiber laser delivers short, high-peak-power bursts ideal for heavy rust and precision cleaning with minimal heat transfer. Other lasers, like CO2 or UV, are generally less suitable or reserved for highly specialized, delicate applications.
Conclusion
Laser rust removal, primarily using the Fiber Laser via laser ablation, is a precise, non-destructive method ideal for daily metal items and valuable metal items. Though more costly than chemical methods, this rust removal equipment offers fast, environmentally friendly cleaning without damaging the base metal. For home use, a 20W to 50W desktop fiber laser engraver is recommended, emphasizing the need for strict safety gear.
