10/22/2017 Beginner's Guide to Rust: Causes And Prevention Through Galvanization

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Causes and of Rust and Protection Through Galvanization

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written by: Finn Orfano edited by: Lamar Stonecypher updated: 9/25/2013

Rust is a process that occurs when oxygen and moisture contact exposed metal. With the
settlement of moisture in dents, and with an increase in the contact period, rust is formed. Rusting
is intensified with high temperatures and increased humidity, and leads to a deterioration in the
metal.

Formation Of Rust

Rust, which is technically known as oxidation, is the process that results when there is an
interactionn between oxygen and various metals for an extended time
period. The oxygen and metal combine at an atomic level creating a new
compound termed an oxide, and the metal bonds are weakened.
When iron or steel are the base metal, then the rust formed is called iron oxide (and similarly
rusted aluminum is called aluminum oxide). Iron and steel are apparently hard in appearance, but
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10/22/2017 Beginner's Guide to Rust: Causes And Prevention Through Galvanization
the minute ruptures and pits in the exposed metal facilitate the penetration
of water molecules, and rust is formed.
Rusting is an electrochemical process that is commenced with the move of
electrons from iron to oxygen, and the process is expedited in salt water.
With the passage of time, and availability of water and oxygen, an iron
body will be converted into rust and be disintegrated.

Damage Due To Rust

Rust is a serious issue, and unless taken

seriously in the initial stages, may be
uncontrollable and
cause extensive
damage by the
deterioration, failure,
or weakening of
components or
appliances. Rust is
extremely harmful to
cars. As the body is
stained, the rust spreads to other parts of the
car body if exposed to extreme moisture in the
weather- and if appropriate rust prevention
measures are not taken.
Electrical appliances and instruments may fail if the metallic parts are rusted since rust is a non-
conductor of electricity. Similarly, the machines and equipment that use magnets may malfunction
due to the inferior magnetic properties of rust.

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Furthermore, since rust formation increases the volume of the initial iron mass, adjacent rusted
parts may be forced apart, causing failure of the machines or assemblies. Rusting of iron in
reinforced concrete bridges may be a source of serious structural problems that may be extremely
dangerous, and also require huge expenditures for repairs.

Rust Prevention By Galvanization

Galvanization is an important metallurgical process for rust prevention that involves the
application of a zinc layer, by electroplating or hot dip galvanizing, on the
iron or steel object desired to be protected. In this process, iron or steel is
dipped in melted zinc at a temperature at which there is a great similarity
between these materials, and an alloy is formed, with a zinc coating at the
exterior surface.

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10/22/2017 Beginner's Guide to Rust: Causes And Prevention Through Galvanization
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The coating of zinc protects the metal part object from oxidation and environmental effects like
extreme temperatures, snow, wind, and rain. Zinc is used since its corrosion resistance
characteristics are better than iron and steel, due to which it forms a physical obstruction against
corrosion, and also shields the exposed steel if the zinc layer is damaged.
Galvanization is not successful at protecting joints and holes. However, it is widelye used for the
protection of iron and steel because it is economical, simple in use, and long lasting.

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