How to remove rust

Removing rust from metal mechanical components and protecting them against future rusting is essential in a variety of industries. Keeping parts rust-free prolongs the life of equipment and machinery, ensuring their durability and full operation.

There are multiple methods for derusting metal parts, including chemical and mechanical processes. However, many of these methods can be laborious, potentially damaging to treated surfaces, harmful to the environment, and pose significant health and safety risks.

Ultrasonic immersion tanks allow parts to be immersed in a deoxidizing solution, eliminating the need for manual intervention and ensuring that the detergent acts optimally. This process ensures uniform and thorough cleaning, protecting metal surfaces and reducing the risks associated with more invasive methods.

 

Removing rust with ultrasonic cleaning machines

How is rust formed?
Rust formation occurs due to an electrochemical reaction in which the metal loses electrons (oxidation) when reacting with oxygen and water present in the environment. This reaction generates a layer of fragile and porous material that weakens the structure of the metal, reducing its strength and durability.

Rust is the result of a corrosion process that occurs when a metal, such as iron or steel, comes into contact with oxygen and moisture for a prolonged period. This chemical process, known as oxidation, results in the formation of a layer of iron oxide, commonly known as rust

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Why is it important to remove rust from metal parts?

The presence of rust on metal components can have serious repercussions in various industries. When mechanical parts are weakened or increased in volume due to corrosion, they can easily break under the demands of production processes. This can lead to machinery failures, production line interruptions or vehicle breakdowns, which not only entails high repair costs and productivity losses, but also poses a risk to worker safety.

Furthermore, rust causes excessive use of materials such as iron and steel. It is estimated that more than 15% of the steel produced industrially is used solely to replace components damaged by corrosion, which entails high expenditure on the acquisition and storage of parts. From an environmental perspective, the impact is also significant. Parts affected by rust, when they deteriorate excessively, become difficult to recycle or reuse, increasing the generation of metal waste.

Implementing effective strategies for rust removal as part of preventive maintenance, in combination with anti-corrosion protective coatings, helps to prolong the useful life of metal components. This not only reduces operating costs and minimizes the need to purchase spare parts, but also optimizes the use of resources and improves sustainability in industrial processes.

Effects of rust on metals

• Structural deterioration: Rust weakens the strength of the metal, making it brittle and prone to failure.
• Loss of functionality: In machinery and industrial parts, corrosion can affect their performance and precision.
• Unkempt appearance: Rust creates reddish or brown stains on the surface of the metal, affecting its aesthetics.
• Increased need for maintenance: Rust must be removed regularly to prevent its advance and preserve the useful life of the material.

 

How to remove rust?

Ultrasonic cleaning: an effective solution against rust
Ultrasonic cleaning machines use high-frequency waves to generate cavitation in a cleaning liquid. This phenomenon allows rust particles to be removed in depth without damaging the part. Unlike other methods, such as sandblasting or aggressive chemicals, ultrasonic cleaning is safer for delicate parts and environmentally friendly.

Advantages of ultrasonic cleaning in rust removal

1. Uniform and deep removal: Reaches hard-to-reach areas, such as internal cavities and complex geometries.
2. Non-abrasive and non-aggressive: Maintains the structural integrity of the material without wearing it down.
3. Reduction of chemicals: Reduces the need for aggressive solvents, making the process more sustainable.
4. Optimization of cleaning time: Compared to manual or mechanical methods, the ultrasonic process is faster and more efficient.
5. Compatible with different materials: It is not only applied to steel parts, but also to alloys, aluminum and other metals susceptible to corrosion.

 

How to use an ultrasonic machine to remove rust

• Prepare the cleaning solution: Use a specific detergent for rust removal, diluted in water according to the manufacturer's recommendations.
• Place the parts in the ultrasonic tank: Ensure that all submerged parts have uniform access to the ultrasonic waves.
• Set the right parameters: Adjust the frequency, temperature and cleaning time according to the level of corrosion present in the parts.
• Rinse and dry the parts: Once the process is finished, it is important to remove any chemical residue and apply a protective coating to prevent re-oxidation.

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Industrial applications of ultrasonic cleaning against rust

This method is widely used in industries such as:

• Automotive: Cleaning of mechanical parts such as cylinder heads, engine blocks and injection systems.
• Aeronautics: Removal of rust on critical components without affecting their precision.
• Metallurgy and manufacturing: Restoration of industrial tools and parts.
• Restoration of machinery and antiques: Recovery of historical parts without compromising their original structure.

Removing rust from metal parts with ultrasonic cleaning machines is an innovative method that combines efficiency, safety and sustainability. Thanks to its ability to remove corrosion without damaging the material, this system has become an essential option in various industries. Investing in ultrasonic technology for metal cleaning not only optimizes maintenance, but also prolongs the life of components and improves their performance.

What is the difference between corrosion and oxidation?
Corrosion is defined as the result of the deterioration of a material when metal atoms on the surface of a metal are oxidized in the presence of oxygen and water. Oxidation is an electrochemical decomposition of the metal due to its exposure to oxygen and water. Corrosion is therefore a type of oxidation.

How to remove rust with DCM Ultrasonic solutions
Periodic maintenance is key to slowing down the formation of rust on metal parts. Therefore, our ultrasonic washers, both manual and automatic, can play a fundamental role as the first phase in the elimination of corrosion. We have equipment designed to adapt to a wide variety of part sizes, which are complemented by high-performance detergents specifically formulated to prevent immediate re-oxidation.

For the effective removal of accumulated rust, we offer an immersion method that offers optimal results with minimal operator intervention. We also have ultrasonic cleaning systems that combine immersion technology with the precision of ultrasound, allowing deep cleaning even on parts with complex and difficult-to-access geometries.

LET US HELP YOU TO REMOVE RUST FROM YOUR PARTS

To combat corrosion, our ultrasonic machines are the ideal solution. Faster results than traditional approaches to removing rust. Investing in ultrasonic technology for metal cleaning not only optimizes maintenance, but also prolongs the life of components and improves their performance.