Creating a distressed or battle-worn look on metal is a popular technique for prop makers, artists, and DIY enthusiasts. Here are the most effective methods to achieve this rugged aesthetic:

1. Sanding and Scratching – Use coarse sandpaper or steel wool to remove paint and create scratches. Focus on edges and high-contact areas for a natural worn effect.

2. Chemical Aging – Apply vinegar, salt, or hydrogen peroxide to accelerate rust formation. For controlled corrosion, use a mix of water and bleach sprayed lightly on the surface.

3. Dry Brushing – Dip a stiff brush in metallic or rust-colored paint, then wipe most of it off before lightly brushing the metal. This highlights texture and adds depth.

4. Heat Distressing – Use a torch to darken areas and create burn marks. This works well for steel and iron, simulating battle damage or extreme wear.

5. Layering Paint – Apply a base coat, then add chipped effects using masking fluid or a wax resist method. Seal with a matte finish for authenticity.

For extra realism, combine these techniques—such as rusting after sanding or adding heat marks over paint layers. Experiment to achieve your desired level of weathering!