Laser Marking Systems / Laser Markers
Laser Rust Removal
No one likes rust—whether that be because it ruins colors, decreases magnetic attraction, weakens structures, or adds unwanted friction—and manufacturers would do away with it entirely if they could. However, rust is a naturally occurring corrosion process caused by water and oxygen exposure to iron or steel. Because of this, it is almost impossible to avoid.
Since rusting can’t be prevented entirely, industries using iron and steel have turned to rust removal techniques to keep their components strong and rust-free. Methods like sandblasting, shot blasting, chemical removal, and laser rust removal are some ways technicians remove rust. However, using a laser rust remover is a standout method among these processes because of its efficiency, precision, and top-tier automation. A laser rust remover can be any laser system or laser marking system so long as it is set to the correct settings for rust removal.
Advantages of Laser Rust Removal
There are many reasons why laser rust removal is used across many industries. For one, it is a quick and effective way to clean metal. Unlike traditional methods, such as sanding or chemical treatments, laser marking systems target only the rust, leaving the underlying material untouched. Laser rust removal is precise, so it's less likely to damage the metal. It's also a more environmentally friendly option since it doesn't involve chemicals or create waste materials.
Laser rust removal is a versatile process. Rusted or oxidized metals like steel, aluminum, and iron are no problem for laser machines. Have complex parts and shapes that are rusty? Not a problem for laser technology. It reaches areas that are hard to access, and the process is faster than manual methods. A rust-removing laser can even reduce downtime for equipment repairs or maintenance, which operators find advantageous.
Applications of Laser Rust Removal
Because lasers offer so many advantages for rust removal, many use cases have evolved. In the aerospace industry, rust is often removed to preserve components like aircraft frames and turbine blades. These precision-made parts often require special care. A laser's accuracy allows operators to remove rust without harming the underlying materials. As a result, the life of expensive components can be extended.
The electronics industry also has instances where rust is problematic. For example, delicate metal connectors and circuit boards may get exposed to oxidation. Since these parts are sensitive to damage, lasers offer a non-invasive way to remove rust without relying on harsh chemicals that could harm the components.
In the automotive industry, lasers help with many manufacturing and restoration projects. They can easily remove rust from smaller, vital components like engine parts while reaching areas that would be difficult to access for other equipment. Because of this, manufacturers can maintain vehicle quality and extend the lifespan of automotive components.
These are just a few applications, but lasers are also a big help for:
- Cleaning surgical instruments without damaging them, ensuring precision and safety.
- Cleaning delicate semiconductor tools and machinery without introducing contaminants.
How KEYENCE Laser Rust Removal Systems Work
The laser rust removal process is an ablative cleaning method that a laser rust removal machine conducts. The laser rust removal machine uses a focused laser beam with high peak power and short pulse to heat the external surface (the rust) to its evaporation point. Left behind is the clean original component.
KEYENCE offers two laser machines that can remove rust—the hybrid laser marker and the fiber laser marker. Both machines offer a non-abrasive way to remove rust without damaging the metal underneath.
KEYENCE’s 3-Axis hybrid laser marker, the MD-X Series, is known for its versatility. A built-in distance sensor continuously monitors the distance to the surface, adjusting the focus accordingly. By detecting unintended changes in the height or angle of the target, the laser rust remover system ensures consistent results and prevents defects across the entire area.
The 3-Axis fiber laser marker, the MD-F Series, is great for metals. It uses a focused beam to vaporize rust layer by layer, giving you precise control. This system has a higher output power to help clean through thicker or more rusted areas more quickly. This is helpful for faster rust removal needs.
KEYENCE Laser Rust Remover Specialties
KEYENCE Laser Rust Remover Feature: XY and Z Tracking
Focused power is a necessity for rust removal. It aims to bring back the original form of the rusted part. Unfocused light is unproductive because it can be too dispersed to effectively remove all of the rust, and it can also have a more unpredictable effect on the surface of the material. To eliminate this concern, KEYENCE has Z tracking to keep the laser in focus to improve the laser rust removal process.
KEYENCE’s hybrid laser marker has a variable lensing system that can adjust the focal distance of the laser marker along with an internal camera to track the parts inside the laser's field of view. This variable lensing system, also known as 3-Axis control, and the internal camera work together to allow the KEYENCE hybrid laser to track the part in the X, Y, and Z direction. This ensures that the laser hits the target point regardless of the part’s positioning, height, and size.
Besides the XY and Z tracking avoiding unnecessary processing, it also assists in the efficiency aspect of laser rust removal for two reasons. First, there’s no need to spend time repositioning every part for the correct angle when removing rust with a laser. Secondly, this enables the assembly line to accommodate various types of components or arrange identical parts in different configurations. In either scenario, the use of XY and Z tracking technology eliminates the laborious tasks associated with rust removal.
KEYENCE Laser Rust Remover Feature: High Peak Power & Short Pulse Laser
Laser ablation, the laser rust removal process, is powered by high peak power and short pulse frequencies. KEYENCE takes laser ablation to the next level with peak powers higher and frequencies faster than other laser models.
- 3 Axis Hybrid Laser Marker MD-X Series
- KEYENCE’s hybrid laser marker has a peak power of 200kW and a pulse of 4 ns. This high peak power is twice that of a conventional YVO4 laser and is ideal for rust removal.
- 3 Axis Fiber Laser Marker MD-F Series
- KEYENCE’s fiber laser has multiple power settings: 30W or 50W. This high wattage competes with the 20W output that conventional fiber lasers have.
KEYENCE Laser Rust Remover Feature: 3-Axis Control
KEYENCE’s rust-removing laser machines are supplied with 3-axis control, which is ideal for the unique challenges of rust removal.
Rust occurs on iron or steel: two versatile metals used across industries for many parts. Cables, surgical instruments, semiconductors, and automobile components exemplify this diverse group. With the diversity of shapes, sizes, and uses, 3-axis control is handy for targeting everything.
3-axis control allows the beam spot to target any shape or size, even if it is non-geometric. Stepped, incline, cylindrical, and cone targets with rust around corners, edges, or inside small areas are quickly and precisely processed with KEYENCE’s laser rust remover.
KEYENCE Laser Rust Remover Feature: High Speed
The high speed of laser rust removal is a helpful asset for tackling large-scale projects that require efficient completion. Laser rust removal is a one-step process that only involves the shot of the laser beam onto the rust for it to evaporate off.
Removing rust with a laser competes with other solutions like chemical rust removal, which can require an overnight process for heavy rust removal.
Choosing KEYENCE for Laser Rust Removal
KEYENCE is an international provider of laser technology that can be tailored for rust removal. KEYENCE utilizes an in-house research and development team to produce the fastest, easiest, and most versatile laser machines that efficiently conduct laser ablation. Whether your rusted parts have tedious curves or sharp edges, KEYENCE’s laser rust removal machine will utilize features to seamlessly remove the rust for a cleaned part.
Where to start on your laser rust removal journey? Contact KEYENCE today! Our team will get back to you immediately with advice about a suitable machine for you and how to demo our products!
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