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What Will Rust Through 1/4" Steel the Fastest

May 18, 2011

Hi, I need to quickly rust through 1/4" steel. What would be the quickest and most effective way to do this? I've seen how people rust steel wool, but that doesn't apply to me. I can't submerge the steel plate in a solution, rather I will be giving it multiple coats of the most effective solution possible.

So far I have used muriatic acid, but I am wondering if there is something that will help me rust through this steel even quicker.

Would greatly appreciate any help.

DJ Meyer
Hobbyist - St. Louis, Missouri

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Hi, DJ. As I recall from Westworld, hydrochloric (muriatic) acid is your best bet for defeating this metal monster.

Because hundreds of people will read this, I remind them that HCl can be a rather dangerous material. Also, HCl is not really a liquid, it's a gas dissolved in water, rather like the carbonation in soda; so if you use it in your basement or attached garage, you may rust your kitchen appliances and bathroom fixtures.

Regards,

Ted Mooney, P.E.
Striving to live Aloha
finishing.com - Pine Beach, New Jersey
May 19, 2011

2-5 % iron (III) chloride solution must work, and it is less toxic than muriatic acid. Strong kitchen salt and water solution is usable too. Electrochemical method is possible too (100 gm salt / 1 lit water object = anode(*), as cathode you can use piece of iron sheet). Hope it helps and good luck!

Goran Budija
- Zagreb,Croatia
First of two simultaneous responses -- May 24, 2011

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Second of two simultaneous responses -- May 24, 2011

I think that the crux of your problem is the 1/4" of steel. This is an awful lot of metal to dissolve. HCl would do the job but the quantity required makes it a hazardous undertaking for home use. You need to understand the first aid requirements and be prepared for things to go wrong - they always do!

A safer alternative would be ferric chloride ⇦ this on eBay or Amazon [affil links] solution but you still have to understand the problems; like how to dispose of the residues.

You also need a trained and trusted helper. Fixing an acid spill is difficult when you have some in your eye and can't see (don't think that goggles never leak!)

There are many ways of making a hole in steel. If you could explain your problem more fully, we may be able to help.

Geoff Smith
Hampshire, England