AN INVESTIGATION REPORT ON

CORROSION AND RUSTING OF IRON

Title Page
Submitted to:
Department of Chemistry

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 Acknowledgements

I would like to take this opportunity to express my deep gratitude and sincere
thanks to _____________ to have given this opportunity to prepare this
informative and interactive project report.
My special thanks goes to our teachers ________________ and all my
Chemistry teachers for their valuable guidance, suggestions and information on
this topic. Also taking this moment to mention all my lab teachers for
facilitating our lab sessions throughout the year.
I can’t forget to offer my sincere thanks to all my teachers who have guided,
aided, and suggested me with ideas related to report writing and corrections
that has made this project a success.
Lastly, I would like to extend my appreciation to my seniors, friends and
classmates for their guidance, advice and support which I have received all the
time.

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Abbreviations
Reaction Abbreviation:
Unit Abbreviation:
aq: Aqueous
gm: gram
s: Solid
l: liter
g: Gas
mol: Mole
e-: Electron
cm: centimeter
hr: Hour
Others:
C: Celsius
M.C. Moisture Content
F: Fahrenheit
C.R. Corrosion Rate
K: Kelvin
Element Symbols:
H: Hydrogen
O2 : Oxygen
C: Carbon
HCl: Hydrochloric acid
CO2: Carbon dioxide
H2S: Hydrogen Sulphide
NaCl: Sodium Chloride
HCO3: Bicarbonate

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 Table of Contents

Title Page.....................................................................................................................
Acknowledgements....................................................................................................
Abbreviations............................................................................................................
Table of Contents......................................................................................................

Introduction................................................................................................................
Metallic Properties of Iron:...............................................................................
Corrosion...........................................................................................................
Rusting...............................................................................................................
Working Principle - Rusting of Iron..........................................................................
Objectives:..................................................................................................................
Methodology..............................................................................................................
Results........................................................................................................................
Discussion..................................................................................................................
Factors affecting rate of Rusting:.....................................................................
Effects of Rusting..............................................................................................
Future Scope of Work:.............................................................................................
Conclusion................................................................................................................
Recommendation......................................................................................................
Prevention of Rust Formation.........................................................................
References................................................................................................................

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Introduction
Iron is one of the widely distributed elements in the nature. It is the most abundant
transition metal in Earth’s solid crust, 4 th among all other elements, and second (to
Aluminum) among metals. Most of this iron is found in various iron oxides, such
as the minerals hematite, magnetite, and taconite. World production of new iron is
over 500 million tonnes a year, and recycled iron add other 300 million tonnes.
Economically workable reserves of iron ores exceed 100 billion tonnes. The main
mining areas are China, Brazil, Australia, Russia and Ukraine, with sizeable
amounts mined in the USA, Canada, Venezuela, Sweden and India. (1)

Iron Symbol Fe Atomic number 26

Key isotopes 56
Fe Iron Atomic Mass 55.85 g./mol
Electron configuration [Ar] 3d6 4s2 Block d
Group 8 Period 4
Melting point 1536 °C Boiling point 2861 °C
State at NTP Solid Density (g /cm3) 7.8 g./cm3 at 20°C
(2)
Metallic Properties of Iron:

It is a lustrous, ductile, malleable, silver gray metal. It is a transitional metal with

varying valency due to its incomplete configuration. It is known to exist in four
distinct crystalline forms. It is also a good conductor as well as a magnetic
substance.
It dissolves readily in dilute acids. Iron is chemically active and forms two major
series of chemical compounds, the bivalent iron (II), or ferrous, compounds and
the trivalent iron (III), or ferric, compounds. (1)
Iron undergoes corrosion; in presence of damp air, but not in dry air. Corrosion is
one of its distinct characteristics such that rusting is a term specific to iron and
iron compounds only.

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Corrosion

Corrosion is a natural process that converts a refined metal or alloys into a more
chemically stable form such as oxide, hydroxide, carbonate or sulfide. It is the
gradual destruction of materials (usually a metal) by chemical or electrochemical
reaction with their environment. (3)
Copper, Zinc, Nickel, Tin and Other precious metals like gold and silver, can
corrode. Copper turns greenish, silver turns black on corrosion. Many
structural alloys corrode merely from exposure to moisture in air.
In fact, rusting of Iron falls under the category of corrosion. While corrosion is
referred to other metals, corrosion of Iron is rusting.

Fig. 1 Corrosion of Copper in Statue of Fig. 2 Corrosion of Fig. 3 Corrosion of Coins of Different
Liberty Silver Alloys

Rusting 

In presence of water, air & carbon-dioxide, the

surface of iron gets covered with a red brown flake
coating called "RUST". Rust is an iron oxide,
usually red oxide formed by the redox reaction of
iron and oxygen in the presence of moisture in air
or water for an extended period of time. This
phenomenon is referred to as rusting. (4) Fig. 4 Rusting of Iron Alloy Bridge

Fig. 5 Rusting of Iron in cycle Fig. 6 Rusting of Iron Chain

Working Principle - Rusting of Iron

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. It consists of hydrated iron (III) oxides,
Fe2O3.nH2O and iron (III) oxide hydroxide

When a piece of iron metal is exposed to humid atmosphere, its gets covered with a red
brown substance called "Rust". Rusting of iron can be explained on the basis of electro
CHEMICAL THEORY.

The overall rusting involves the following steps:

Oxidation occurs at the anodes of each electrochemical cell. Therefore, at each anode
neutral iron atoms are oxidized to ferrous ions.

1- At anode:
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.
Fe(s) → Fe2+(aq) + 2e−

2- At cathode:
The electrons are taken up by hydrogen ions (reduction takes place). The H+ ions are
obtained either from water or from acidic substances in water.
H2O → H+ + OH− OR CO2 + H2O→ H++ HCO3−

 The hydrogen atoms on the iron surface reduce dissolved oxygen.

4H+ +O2 → 2H2O

Therefore, the overall reaction at cathode of different electrochemical cells may be written
as,
4H+ + O2 + 4e−→ 2H2O

The overall redox reaction may be written by multiplying reaction at anode by 2 and
adding reaction at cathode to equalize number of electrons lost and gained.

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Oxidation half reaction: Fe(s) → Fe2+ (aq) + 2e] ×2

Reduction half reaction: 4H+ + O2+ 4e− → 2H2O

Overall cell reaction: 2Fe(s) + 4H++ O2 → 2Fe2+ (aq) + 2H2O

The ferrous ions are oxidized further by atmospheric oxygen to form rust.
4Fe2+ (aq) + O2 (g) + 4H2O → 2Fe2O3 + 8H+
Fe2O3 + xH2O → Fe2O3 .xH2O

Therefore, this is the mechanism of rust formation of Fe2O3. xH2O.

(5)

Objectives:
The objectives of this investigation report are as:
 To learn the mechanism that is responsible for rusting of iron.
 To determine the factors affecting rusting of iron.
 To know the type of reaction that occurs in rusting

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 To determine the possible ways to minimize rusting.

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Methodology
Report Methodology:
We have conducted a qualitative investigation and prepared a report on the
Mechanism, Causes, and the Effects of rusting.
Besides the experimental observation, the methodology for this report making
was:
Secondary sources:
We have made use of Internet and Reference books containing mechanism of
rusting. The graphs shown in the report are given from past experiments that are
posted in the Internet which are given in reference.
Experimental Investigation: Rusting Of Iron Nail
Objective: To show how rusting is affected by water and air medium

Materials required:
SN APPARATUS CHEMICALS
1 Test tubes Normal Tap Water
2 Rubber Stopper Boiled Water
3 Iron nails Anhydrous Calcium Chloride (CaCl 2)
4 Burner Mustard oil
5 Test Tube Holder
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Procedure:

 Three test tubes A, B and C were taken and a clean iron nail placed in each.
 In the test tube A, the nail was kept with water.
 In the test tube B, the nail was kept with boiled water. Also some oil was poured in test
tube B to form a layer over boiled water which will prevent the entry of air in water.
 In the test tube C, nail was kept with anhydrous calcium chloride. Anhydrous CaCl2 is
drying agent that absorbs all the moisture present in the air of test tube.
 These test tubes were kept undisturbed for some days.

Results
Observation:
Ob. Sample: Conditions Observation Inference
Tube A Both Air and Water Rust was formed. Rust forms in presence of air
and water (and/or CO 2).
4Fe + 3O2 + 6H2O → 4Fe(OH)3
Tube B Water, No Air No Rusting. Rust doesn’t form in absence
(Boiled water+ Oil) of air.
Tube C Air, No water No Rusting. Rust doesn’t form in absence
(Anhydrous CaCl2) of moisture.

Conclusion:
Rust is formed by prolonged action of water, oxygen and carbon dioxide on iron
under the suitable conditions.
(6)

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Discussion
Factors affecting rate of Rusting:

 Moisture:
The corrosion of iron is limited to the availability of water. Exposure to moisture;
whether in the form of dew, rain or condensation is the most common reason for
rusting. In humid, tropical areas, condensation can be found on surfaces which turns into

an alkaline reaction with metal or absorbs carbon dioxide to create a dilute acid.

 Air concentration:

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Like water, oxygen increases the rate of corrosion. Corrosion can take place in an
oxygen-deficient environment, but the rate of corrosion reaction is much slower.

 Temperature
Corrosion reactions are usually electrochemical in nature and accelerated with increasing
temperature; therefore corrosion process takes faster in warmer environments than the
cooler ones. Essentially, every 50°F (10°C) increase in the temperature can double
corrosion activity. 

 Salt (ions present):

Iron tends to rust faster in the sea, due to the presence of various salts. Saltwater
contains many ions that speed up the rusting process via electrochemical reactions.
Chloride ions are
usually the most

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destructive with sulphate and other sulphur ions also presenting major problems.
Chloride ions have a destructive effect on the protective properties of any rusts produced
by preventing the formation of the more protective, densely packed oxides that
repeatedly causes oxidation.

 Acid:
If the pH of the environment surrounding the metal is low, the rusting process is
quickened. The rusting of iron speeds up when it is exposed to acid rains. Higher pH
inhibits the corrosion of iron. Acid gases such as CO 2, can also dissolve in a film of
moisture in contact with metal.

 Time of Exposure: In case of steel, the corrosion is increasing with increasing time
of exposure.

 Impurities: Pure iron tends to rust more slowly when compared to iron containing a
mixture of impurities.

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Effects of Rusting

1. Weakens material due to prolonged corrosive action by replacing strong, pure metal
with a flaky powder. It will have huge economic impacts on bridges, and other
constructions.
2. Rust that has developed in auto body parts stops vehicles from functioning properly.
It destroys vital mechanical components like a vehicle's engine or transmission.
3. Rust alters the appearance of metal components. Rust replaces the sleek look of metal
with a rougher, irregular surface. Rust also discolors the surface of metal objects.
Rusted metal acquires a reddish or orange color.
4. Corrosion sometimes becomes advantageous when a surface produces an oxide film
coating that will keep corrosion from proceeding further; which happens in the case
of aluminum metal.
5. Metal is used in many equipment pieces to conduct electricity. While normal metal is
a good conductor of electricity, rusted metal is not as efficient a conductor.
6. Rust development in metal components of equipment weakens magnetic attraction.

Future Scope of Work:

 Engineering metallurgy
 Electrochemistry
 Corrosion Science / Principles of Corrosion
 Corrosion engineering:
It is an engineering specialty that applies scientific, technical, engineering skills, and
knowledge of natural laws and physical resources to design and implement materials,
structures, devices, systems, and procedures to manage corrosion.
 Nano Technology:
The main research on corrosion is conducted by governments and industries,
resulting in new science and inventions on corrosion protection. For the last two
decades, the role of nanotechnology is increasing the invention of technological
advances to control corrosion.

Conclusion
Hence, we have hence investigated on topics as Corrosion, Rusting, Mechanism of
Rusting, Cause of Rusting, Effects of Rusting. We can see that the major variables that
drastically affect rusting are moisture and presence of atmospheric air. Also, other

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factors such as temperature, time of exposure and the acidity of the medium where the
metal is kept also determines the rate of rusting.

Recommendation
Prevention of Rust Formation

Many investigation regarding more

economical and permanent solution to
prevent rusting are still going on. The short
experiment already tells us what can be done
for the prevention of rust formation. Some of them are explained in detail:

1. Use Alloys that are Resistant to Rusting

While all metals corrode, they each corrode at different rates. This is why alloys, which
are made from two or more different metals, are resistant to rusting. Some alloys of iron
are rust-resistant. Examples include stainless steel (which features a layer of chromium
(III) oxide) and weathering steel.COR-TEN steel rusts at a relatively slower rate when
compared to normal steel. In this alloy, the rust forms a protective layer on the surface of
the alloy, preventing further corrosion.

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 Fig. COR-TEN steel bridge that has protective layer of rust on the surface

2. Coa
ting
s
Many
types of

coatings can be applied to the surface of the exposed metal in order to prevent corrosion.
Common examples of coatings that prevent corrosion include protective paints, wax
tapes, and varnish. Smaller objects are coated with water-displacing oils. Many
industrial machines and tools made of iron are coated with a layer of grease, which
lubricates the metal to reduce friction and prevents rusting at the same time.

3. Dry coatings:
These products work on the same principle as oil—creating a protective barrier against
rust—but they don’t leave residue behind. For metal parts or components that need to
stay clean or provide a solid grip, a rust preventative dry coating is ideal. Dry coatings
can also be used in combination with other ways to prevent rust. For example, you might
use a dry coating over a painted or powder coated object to increase the level of
protection.

4. Galvanization

 Galvanization is the process of applying a protective layer of zinc on a metal. It is a

very common method of preventing the rusting of iron.
 This can be done by dipping the metal to be protected in hot, molten zinc or by the
process of electroplating.
 Zinc is a relatively cheap metal that sticks to steel easily. It also offers cathodic
protection to the iron surface by acting as an anode. The zinc layer is corroded
instead of the iron due to this.
 The disadvantages of galvanization are that it only provides protection from
corrosion for a limited amount of time since the zinc layer is eaten up in the process.

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 It is not very effective in highly corrosive areas (where cadmium coating can be used
instead).

5. Blueing
 The process of blueing steel actually creates a new layer that is similar to rust, but
much less damaging. Blueing creates a layer of magnetite, also called black iron
oxide, and gives metals a black or namesake blue appearance.
 Blueing is usually accomplished by applying high temperatures and a salt solution.
This process is commonly used to economically protect firearms from rusting.
 Blueing works best when the steel is also regularly oiled.

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References
1. Iron (Fe) - Chemical properties, Health and Environmental effects [Internet]. [cited 2022
Mar 11]. Available from: https://www.lenntech.com/periodic/elements/fe.htm

2. Singh R. Iron (Fe) - Melting Point, Atomic Mass & Number, Chemical and Physical
Properties with Symbol [Internet]. BYJUS. [cited 2022 Mar 11]. Available from:
https://byjus.com/chemistry/iron/

3. Corrosion. In: Wikipedia [Internet]. 2022 [cited 2022 Mar 11]. Available from:
https://en.wikipedia.org/w/index.php?title=Corrosion&oldid=1074272579

4. Rusting of Iron, Project Report Rusting of Iron - Chemistry Projects [Internet]. [cited 2022
Mar 11]. Available from:
http://www.allprojectreports.com/CBSE-HBSE-School-Projects/Chemistry-Project-Report/
rusting_of_iron.htm

5. Mechanism of Rusting of Iron

https://www.vedantu.com/question-answer/
6. Experimental investigation on rusting of iron
https://funscience.in/experiment-to-prove-that-air-and-water-are-necessary-for-rusting-of-
iron/
Graph 1: Relationship between Soil Properties and Corrosion of Carbon Steel. 2012.
https://www.researchgate.net/figure/Relationship-between-corrosion-rate-and-
moisture-content-according-to-soil-types_fig5_259760804
Graph 2: Corrosion of Low Carbon Steel Under the Joint Effects of Time-Temperature-Salt
Concentration. Available from:
https://www.frontiersin.org/article/10.3389/fmats.2019.00010
Graph 3: Relationships between corrosion rate and temperature for mild steel [ResearchGate]
Graph 4: Chuka CE. Investigation Of The Effect Of Corrosion On Mild Steel In Five Different
Environments. 2014;3(7):5.

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