Summary for bond rusted metal Discussion
Heavily rusted metal bonding is the core issue here: Angela Smith wants to make decorative marine-debris sculptures without stripping away the rust that gives the pieces character, but she worries the powdery corrosion will not bond well. She says structural strength is less important than long-term stability. In response, Danielsville, Georgia USA suggests that if she does not want to build an underlying frame with fasteners, she could grind down the rust only in the joint areas and then weld, solder, or use an epoxy, followed by a lacquer. He also notes that holes can be drilled and fasteners used if needed. The practical takeaway is that some rust removal at the bond line, plus epoxy or mechanical fastening, is likely more reliable than trying to bond directly to loose rust alone.
Q. I have recently become interested in collecting marine debris metals for the purpose of creating sculptures. I have an ample supply of materials to work with, but I’m insure of how to construct the actual sculptures. The heavy rust and corrosion is what gives each piece of debris it’s interesting character, so I don’t want to strip the pieces down to uncompromised metal, but I realized the powdery finish of rust makes a poor surface for bonding. Since the pieces will just be decorative I don’t need a high degree of structural integrity, but I do need them to stay intact long term. I am planning to experiment with two-part epoxies, but I thought I would check to see if anybody with experience and expertise could point me in the right direction. Thanks!
Angela Smith
Hobby Artist – Danielsville, Georgia USA
February 3, 2017
A. Hi Angela,
It sounds like you are not interested in making an underlying frame with fasteners attaching the rusted articles. In that case, a couple of ideas come to mind. Perhaps grind down the rust in the joint areas and then weld, solder or use an epoxy followed by a lacquer. Holes can be drilled and fasteners can be used as well.
Blake Kneedler
Feather Hollow Eng. – Stockton, California
February 5, 2017