LIONS ENGLISH SCHOOL, SILVASSA-396239

RUSTING OF
IRON

SUMMITED BY : KISHAN CHAUHAN

CLASS: XII
ROLL.NO: 20
 ACKNOWLEDGEMENT

I would like to express my sincere gratitude to Mrs. Ketna Chauhan,

My Chemistry Teacher, for her invaluable guidance, insights, and
support throughout the development of this project on the Rusting of
iron. Her expertise has greatly deepened my understanding of
complex chemistry concepts. I am also grateful to our Principal, Mr.
Nirali Pareek, for fostering a supportive academic environment that
encourages research and exploration. Their dedication to student
learning has been invaluable, allowing me to broaden my knowledge
and confidence in chemistry. This project would not have been
possible without their unwavering support

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S.NO PAGE.NO
TOPIC
1 INTRODUCTION 3

2 GALVANIC CORRISION 4

3 MECHANISM OF RUSTING 5-6

4 RUSTING IN NON-METALS 7-9

5 EXPERIMENT: RUSTING OF IRON 10

6 REQUIREMENT 11

7 PROCEDURE 12

8 OBSERVATION TABLE & CONCLUSION 13

9 FACTOR PROMOTING RUST 14

10 METHODS OF PREVENTION OF RUSTING 15

11 CONCLUSION 16

12 BIBLOGRAPHY 17

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 INTRODUCTION
Rust is an iron oxide,
usually red oxide
formed by the redox
reaction of iron and
oxygen in the presence
of water or air
moisture. Several forms
of rust are
distinguishable both
visually and by
spectroscopy, and form
under different
circumstances. Rust
consists of hydrated
iron (III) oxides
Fe2O3.nH₂O and iron
(III) oxide hydroxide
(FeO (OH), Fe (OH)3.

Given sufficient time, oxygen and water, any iron mass will eventually convert
entirely to rust and disintegrate, Surface rust is flaky and friable, and provides no
protection to the underlying iron, unlike the formation of patina on copper
surfaces, Rusting is the common term for corrosion of iron and its alloys, such
as steel. Many other metals undergo equivalent corrosion, but the resulting
oxides are not commonly called rust.
Other forms of rust exist, like the result of reactions between iron and chloride
in an environment deprived of oxygen — rebar used in underwater concrete
pillars is an example — which generates green rust.

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 GALVANIC RUSTING
DEFINATION. Galvanic corrosion (also called bimetallic corrosion) is an
electrochemical process in which one metal corrodes preferentially when it is in
electrical contact with another, in the presence of an electrolyte

EXAMPLE- A common example of galvanic corrosion occurs in corrugated

iron, a sheet of iron or steel covered with a zinc coating. Even when the
protective zinc coating is broken, the
underlying steel is not attacked. Instead,
the zinc is corroded because it is less
noble: only after it has been consumed
can rusting of the base metal occur in
earnest. By contrast, with a traditional tin
can, the opposite of a protective effect
occurs: because the tin is more noble than
ton
the underlying Steel, When the tin
coating is broken, the Steel beneath is
immediately attacked preferentially.

Statue Of Liberty
A spectacular example of galvanic
corrosion occurred in the Statue of Liberty
when regular maintenance checks in the
1980s revealed that corrosion had taken place between the outer copper skin and
the wrought iron support structure.
Although the problem had been Copper Ri anticipated when the structure was
built by Gustave Eiffel to Frédéric Bartholdi's design in the 1880s, the
insulation layer of shellac between the two metals had failed over time and
resulted in rusting of the iron supports. An extensive renovation requiring
complete disassembly of the statue replaced the original insulation with PTFE,
the structure was far from unsafe owing to the large number unaffected
connections, but it was regarded as a precautionary measure to preserve a
national symbol of the United States.

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 MECHANISM OF RUSTING
OVERVIEW — The theory of rust can be explained by taking the example
of rusting of iron. The theory is called electrochemical theory because it
explains the formation of rust on the basis of formation of
electrochemical cells on the surface of the metal.

The overall rusting involves the following steps:

(i) Oxidation occurs at the anodes of each electrochemical cell. Therefore, at
each anode neutral iron atoms are oxidised to ferrous ions. At anode:
Fe(s) → Fe2+(Aq) + 2e−
Thus, the metal atoms in the lattice pass into the solution as ions, leaving
electrons on the metal itself. These electrons move towards the cathode
region through the metal.
(ii) At the cathodes of each cell, the electrons are taken up by hydrogen
ions (reduction takes place). The ions are obtained either from water or
from acidic substances (e.g., CO2 in water).
H2O →H+ + OH- or CO2 + H20 → H+ + HCO-3
At cathode:
H+ + e- → H
The hydrogen atoms on the iron surface reduce dissolved oxygen,
4H + 02 → 2H20

Therefore, the overall reaction at cathode of different electrochemical cells

may be written as,
4H+ + O2 + 4e- → 2H20

(iii)The overall redox reaction may be written by multiplying reaction at

anode by
2 and adding reaction at cathode to equalise number of electrons lost
and gained
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Oxidation half reaction:

Fe (s) → Fe2+(Aq) + 2e- ] *2 ( E= -0.44V)

Reduction half reaction

4H+ + O2 + 4e- → 2H20 (E=1.23V)

Overall cell reaction:

2Fe(s) + 4H+ + O2 → 2Fe2+(Aq) + 2H2O (Ecell= 1.67V)
The ferrous ions are oxidised further by atmospheric oxygen to form rust.

4Fe2+(Aq) + 02(g) + 4H20 → 2Fe203 + 8H+

Fe2O3 + xH2O→ Fe2O3.xH20
It may be noted that salt water accelerates corrosion, this is mainly due to the
fact that salt water increases the electrical conduction of electrolyte solution
formed on the metal surface. Therefore, rusting becomes more serious problem
where salt water is present.

Schematic representation of mechanism of rusting of iron

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 RUSTING IN NON-METALS
INTRODUCTION — Corrosion is often thought of as the oxidation of metals
such as iron, but ceramics also corrode, or react with their environment,
Concrete; for example, generally is very stable, but it contains calcium
hydroxide and calcium aluminate, which are attacked by sulphates, such as
calcium sulphate often present in ground water. Tungsten carbide, usually
highly resistant to corrosion, is destroyed in less than a week of contact with
sulphuric acid, 1-12S04.

CERAMICS - Most of the ceramic’s material are almost immune to corrosion.

The strong ionic/covalent bonds that hold them together leave very little free
chemical energy in the structure. So, they can be thought of as already corroded.
An example of corrosion protection in ceramics is the lime added to soda-lime
glass to reduce its solubility in water.
POLYMERS • Corrosion on polymers, both plastics and rubber materials, is in
many cases similar to metals but in other cases it looks very different. Corrosion
attacks on polymers are often hard to discover, the material may look normal
but can in fact be embrittled and have lost its mechanical strength.
Mechanical stressed polymers applied in chemical environments may initiate
cracks on the surfaces. These cracks can thereafter propagate through the
material either as a result of the mechanical stresses or in combination with
continuing chemical attack. Corrosion Of polymers can be divided into either
chemical reaction or physical interaction.

CHEMICAL REACTION: Polymers consist of a network with molecular chains

mainly consisting of carbon, hydrogen and oxygen. Corrosion by chemical
reaction changes the configuration of the polymer chains. Listed below are
some of the environments that cause chemical reactions in polymers.
1, Heat: Chain scission will occur when polymers are exposed to heat above a
specified temperature limit, which is unique for each type of polymer.

2 UV- radiation: In the presence of oxygen, LIV-radiation can cause

breakdown of the polymer chains.

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3, Ozone; Attacks from ozone on unsaturated polymers (e.g., natural rubber)
under stress, causes Characteristic tracks.
4. Wilier: Absorption of water at elevated temperatures causes hydrolysis of
certain groups in a polymer chain (e.g., urethane and ester groups). Hydrolysis
weakens the polymer since the backbone Structure is altered.

PHYSICAL INTERACTIONS - Physical effects on polymers are caused by

interaction with the environment. This may lead to swelling» dissolving or
leakage of additives. The interaction is dependent on diffusion of substances
into the polymer, and the process is in some cases reversible.
Organic substances usually affect polymers through physical interaction, while
substances like strong acids or bases normally result in an irreversible
breakdown of polymers.

RUSTED GLASS

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 RUSTED GLASS

PREVENTION OF RUSTING IN GLASS. Laboratory scale procedures and

practical tests were used to study the problem of glass ware corrosion
(Permanent Filling) in domestic mechanical dishwashers. Result of these tests
showed glassware corrosion to be caused by alkali attack of the glass structure,
It was also found that sequestrates such a sodium triphosphates greatly
accelerate the corrosive action Of alkali, Silicates, certain metals and metal
oxides Were found to inhibit glassware corrosion. The basis for this inhibiting
effect is believed to be adsorption on the glass surface of reaction products of
these materials in an alkaline solution.

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 EXPERIMENT - RUSTION OF IRON NAIL
OBJECTIVE: TO STUDY THE EFFECT OF METAL COUPLING ON RUSTING OF IRON
AIM —In this project the aim is to investigate effect of the metals
coupling on the rusting of iron. Metal coupling affects the rusting of iron.
If the nail is coupled with a more electro-positive metal like zinc,
magnesium or aluminium rusting is prevented but if on the other hand it
is coupled with less electro —positive metals like copper, the rusting is
facilitated,

Potassium hexacyanoferrate(lll) solution

Phenolphthalein indicator

APPARATUS - COUPLING ON RUSTING OF IRON

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 EQUIPMENT REQUIRED

S.NO EQUIPMENTS
1 Two Petri dishes
2 Four test-tube

3 Four iron nails

4 Beaker

5 Sand paper

6 Wire gauge

7 Gelatine

8 Copper, Zinc and Magnesium strips

9 Potassium ferricyanide solutions

10 Phenolphthalein

Phenolphthalein Potassium Ferricyanide Solution

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 PROCEDURE
1, At first, we have to clean the surface of iron nails with the help of sand paper.
2. After that we have to wind zinc strip around one nail, a clean copper wire around
the second and clean magnesium strip around the third nail. Then to put all these
three and a fourth nail in Petri dishes so that they are not in contact with each
other
3. Then to fill the Petri dishes with hot agar-agar solution in such a way that only
lower half of the nails are covered with the liquids
4. 4, Keep the covered Petri dishes for one day or so.
5. The liquids set to a gel on cooling. Two types of patches are observed around
the rusted nail, one is blue and the other pink blue patch is due to the formation
of potassium Ferro ferricyanide where pink patch is due to the formation of
hydroxyl ions which turns colourless phenolphthalein to pink.

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 OSERVATION TABLE
S.NO METAL PAIR COLOUR OF NAIL RUSTS
PATCH OR NOT

1 IRON- ZINC PINK NO

2 IRON- MAGNESIUM PINK NO

3 IRON. COPPER BLUE YES

CONCLUSION

It is clear from the observation that coupling of iron with more

electropositive metals such as zinc and magnesium resists
corrosion and rusting of iron. Coupling of iron with less
electropositive metals such as copper increases rusting

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 FACTORS PROMOTING RUSTING
Four elements need to be present for corrosion to occur and collectively referred
to as the corrosion cell: an anode a cathode G), a metallic conductor and an
electrolyte, Changing the potency of the electrolyte affects the rate of corrosion.
Corrosion rates are determined by a variety of factors: however. five factors do
play an overwhelmingly important role in determining corrosion rates.
Oxygen: Like water, oxygen increases the rate of corrosion, Corrosion can take
place in an oxygen-deficient environment, but the rate of the corrosion reaction
(and destruction of the metal) is generally much slower. In immersed
conditions, if an electrolyte is in contact with one area of metal containing more
oxygen than the electrolyte in contact with another area of the metal, the higher
oxygen concentration area is cathodic relative to the remaining surface. An
oxygen concentration cell then forms, which results in rapid corrosion.
Temperature: Corrosion reactions are electrochemical in nature and usually
accelerate d with increasing temperature; therefore, corrosion proceeds faster in
warmer environments than in cooler ones,
Chemical Salts: Chemical salts increase the rate of corrosion by increasing the
efficiency (conductivity) of the electrolyte. The most common chemical salt is
sodium chloride, a major element of seawater. Sodium chloride deposited on
atmospherically exposed surfaces also acts as a hygroscopic material it extracts
moisture from the air), which then increases the corrosion in non-immersed
areas.
Humidity: Humidity and time-of-wetness playa large role in promoting and
accelerating corrosion rates, Time-of-wetness refers to the length of time an
atmospherically exposed stipitate has sufficient moisture to support the
corrosion process. The wetter the environment, the more corrosion is likely to
occur,

Pollutants: Acid rain (a chemical by-product from manufacturing and

processing plants), and chlorides (in coastal areas) promote corrosion. Acid
gases, such as carbon dioxide, can also dissolve in a film of moisture in contact
with the metal.

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 METHODS OF PREVENTING OF RUSTING
1. Barrier Coatings - One of the easiest and cheapest ways to prevent
corrosion is to use barrier coatings like paint, plastic, Or powder. Powders,
including epoxy, nylon, and urethane, are heated to the metal surface to
create a thin film, Plastic and waxes are often sprayed onto metal surfaces.
Paint acts as a coating to protect the metal surface from the
electrochemical charge that comes from corrosive compounds. Today’s
paint systems are actually a combination of different paint layers that serve
different functions. The primer coat acts as an inhibitor, the intermediate
coat adds to the paint's overall thickness, and the finish coat provides
resistance to the environmental factors.

2. Hot-Dip Galvanization. This corrosion prevention method involves

dipping Steel into molten Zinc. The iron in the Steel reacts With the Zinc
to create a tightly-bonded alloy coating which serves as protection. The
process has been around for more than 250 years and has been used for
corrosion protection of things like artistic sculptures and playground
equipment. Compared to other corrosion prevention methods,
galvanization is known for lower initial costs, sustainability and versatility

3. Alloyed Steel (Stainless) - Alloyed steel is one of the most effective

corrosion prevention methods around. combining the properties of various
metals to provide added strength and resistance to the resulting product,
Corrosion resistant nickel, for example, combined with oxidation-resistant
chromium results in an alloy that can be used in oxidized and reduced
chemical environments. Different alloys provide resistance to different
conditions, giving companies greater flexibility.

4. Cathodic Protection • Cathodic protection protects against galvanic

corrosion, which occurs when two different metals are put together
and exposed to a corrosive electrolyte. To prevent this, the active sites
on the metal surface need to be converted to passive sites by
providing electrons from another source, typically with galvanic
anodes attached on or near the surface. Metals used for anodes
include aluminium magnesium, or zinc

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 CONCLUSION
The process of rusting, scientifically known as oxidation, is a significant
phenomenon affecting iron and its alloys. This chemical reaction occurs when
iron reacts with oxygen in the presence of water or moisture, leading to the
formation of iron oxide or rust. Rusting not only deteriorates the structural
integrity of iron objects but also results in significant economic costs due to the
need for repairs and replacements.

Understanding the conditions that accelerate rusting, such as high humidity,

exposure to saltwater, and the presence of acidic pollutants, helps in developing
preventive measures. Protective coatings, galvanization, and the use of rust-
resistant alloys are effective methods to inhibit rust formation and prolong the
lifespan of iron materials.

In conclusion, rusting of iron is a natural process with considerable practical

implications. By studying and mitigating the factors that contribute to rusting,
we can better preserve and maintain iron structures and tools, ultimately leading
to more sustainable use of iron in various applications.

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 BIBLOGRAPHY
• Websites

• National Centre for Biotechnology Information. "Rust Chemistry: How

Does Rust Form?" Retrieved from
https://www.ncbi.nlm.nih.gov/pmc/articles/PMC3000000.
• American Chemical Society. "Understanding the Chemistry of Rust,"
Retrieved from
https://www.acs.org/content/acs/en/education/whatischemistry.

• Online Resources

• Khan Academy. "Chemical Reactions: Rusting." Retrieved from

https://www.khanacademy.org/science/chemistry.

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