How to remove rust with flap discs?

Flap discs are a versatile, practical and highly productive option for DIY and professional jobs. These discs provide grinding, deburring and finishing operations all in one and at a lower cost than other alternatives. Additionally, they also perform clean cuts with greater benefits than standard abrasive discs.

Thanks to all the advantages they provide to the user, the flap discs They are highly preferred products in the market. These discs have various configurations, to work on different surfaces more efficiently. Thus, we can find flap discs to work on wood, plastic, ferrous and non-ferrous metals; and other discs for working only on metals.

In this publication we will detail one of the processes that you can execute with the use of the flap discs: the rust removal.

Remove rust with a flap disc

For those cases in which you want to recover the original appearance of a material, eliminating corrosion from its surface, you can use an angle grinder with a disco flap installed.

The rust removal It can be done easily, if a series of steps are followed and the following indications are taken into account. Let’s go then, How to remove rust from metal?

First of all, we must emphasize that for the rust removal The use of flap discs containing non-woven abrasives, discs made of aluminum oxide, silicon carbide or zirconium, is recommended. With this in mind, you can proceed with the recovery of the material.

Flap disc – Zirconium

• Before starting work, be sure to use the appropriate personal protective equipment: gloves, goggles, and hearing protectors.
• Additionally, you can use an apron and sleeve extensions for greater security.
• Remove any garments or accessories that could get caught during the work, such as rings, chains, bracelets or watches.
• Disconnect the angle grinder from the electrical connection or remove the battery for a cordless machine before installing the flap disc.
• Only use discs with the appropriate diameter for the machine support.

Flap discs – Installation on angle grinder

• Install and adjust the blade to the grinder without over-adjusting.

Flap discs – Adjustment on angle grinder

• Spin the disc without applying it to any surface, as a test.
• Secure the material or workpiece, to prevent it from moving while you remove the rust.
• Hold the machine firmly and position your body so that you can maneuver freely and comfortably.
• Turn on the grinder again and apply the disk on the surface to be worked, at an angle of between 15 and 30 degrees, making small back and forth movements.

Flap discs – Inclination over workpiece

• Go over the work surface evenly, until all the rust is removed from it.
• After the job is finished, turn off the machine and wait for the disco flap come to a complete stop, before placing it somewhere.

Flap disc with non-woven abrasive

Safety rules when using flap discs

In this section we indicate the safety regulations that must be implemented during work with flap discs. Compliance with these standards will allow you to carry out quality work without any inconvenience.

Flap disc – Aluminum oxide

• Avoid using flap discs that have been dropped or show visible damage, such as cracks or breaks.
• You should always use clamping plates with the appropriate diameter to fix the disc.
• Never over tighten the fixing nuts of the disco flap.
• Check the grinder for any damage or wear.
• Validate that the power of the machine is adequate to avoid an irregular operation of the disc.
• The flap discs they should only be used for the jobs for which they are designed.
• Do not exceed the maximum working speed of the disk.
• Make sure the protective shell of the tool it is always well positioned and anchored.
• Before starting work with the angle grinder, hold it at an angle downwards, away from your body and turn it on with the blade idle until it reaches its maximum speed. In this way you verify that the disco flap is well adjusted.
• Be careful when mounting the disc on the machine. Follow the manufacturer’s directions for this process.
• Only discs with the appropriate diameter and accepted by the grinding machine should be used.
• The blade must not be struck sharply against the workpiece. Work should be done smoothly and with increasing pressure until a suitable pressure point is found.
• The flap discs They should be used at a 15 to 30 degree angle to the workpiece. An excessive incline could cause accidents.

Flap disc – Silicon carbide

With the use of a disco flap Properly and following the indications indicated in this note, you will be able to remove all the oxide from any surface, and restore the useful life of your metal parts.