Our vents/registers get a little rusty, and I think it's because we have a humidifier attached to our furnace. We've painted them and eventually they get a little rusty again...the clear acrylic sealer suggestion sounds like a good idea and is one I plan on trying.
I would suggest to remove the covers and spray them lightly with clear acrylic sealer. The sealer is available in the hardware stores or any craft store.
Why are they getting rusty? I would address that issue first. Is this in an area that gets wet such as a bathroom or kitchen? Is it under a window that gets left open? They should not be getting so wet to rust. Maybe the vent needs to be moved or a leak addressed? If in a bathroom maybe a vent/fan needs to be installed or used. You could coat the vent with a clear poly sealer for outdoor use, but most of those are made for wood applications, or try painting it with rustoleum paint, which is designed to prevent rust.
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