GOVERNMENT DEGREE AND P.G .

COLLEGE (A)
SIDDIPET

DEPARTMENT OF U.G CHEMISTRY

STUDENT PROJECT REPORT
Title of Project
Rusting of Iron

1
 STUDY OF RUSTING OF IRON

PROJECT WORK

(2023-2024)

DEPARTMENT OF U.G CHEMISTRY

GOVERNMENT DEGREE AND P.G . COLLEGE (A)

SIDDIPET

SUBMITTED BY
NAME H.T.NO. GROUP
1.DHOVURI GURUDEV 6025-21-578-001 BSC[MCCs]
2.KESHABOINA MADHU 6025-21-578-003 BSC[MCCs]
3.VANAM AKHILA 6025-21-441-049 BSC[MPC]
4.VAJJA THIRUPATHI 6025-21-441-048 BSC[MPC]
5.VANMA BHARATH 6025-21-441-050 BSC[MPC]
6.VATTU PAVAN KUMAR 6025-21-441-052 BSC[MPC]

PROJECT SUPERVISOR

Dr.K.RAVIKUMAR

LECTURER IN CHEMISRTY

DEPARTMENT

GOVERNMENT DEGREE COLLEGE (A ),SIDDIPET ,TELANGANA

2
 CERTIFICATE

This is to certify that the dissertation entitled”RUSTING OF IRON ” submitted to

Osmania University for the partial fulfillment of the requirements for the award
of degree of Bachelor of Science under the guidance of Dr K.RAVIKUMAR at
Government degree college Siddipet(Autonomous), and the contents of the
dissertation do not form the basis for the award of any other degree or diploma
of the candidate from this or any other University elsewhere.

DATE: PRINCIPAL

Dr.CH.PRASAD

3
 CERTIFICATE

This is to certify that the dissertation entitled”RUSTING OF IRON ” submitted to

Osmania University for the partial fulfillment of the requirements for the award
of degree of Bachelor of Science under the guidance of Dr.K.RAVIKUMAR at
Government degree college Siddipet(Autonomous), and the contents of the
dissertation do not form the basis for the award of any other degree or diploma
of the candidate from this or any other University elsewhere.

HOD OF CHEMISTRY DEPARTMENT

Dr.VASAM SREENIVAS

4
 CERTIFICATE

This is to certify that the student study project that is RUSTING OF

IRON being submitted by B.Sc. MPC & MCCS STUDENTS in partial
fulfillment for the STUDENT STUDY PROJECT in CHEMISTRY is a record
of bonafide work carried out by them under my guidance and
supervision. The results embodied in this student study project have
not been submitted to any other University or Institute for the award
of any degree or diploma.

Dr.K.RAVIKUMAR

M.Sc.,B.Ed,Ph.D

Lecturer in chemistry

5
 DECLARATION

We hereby declare that the contents presented in the student study

project entitled RUSTING OF IRONthat is being submitted in partial
fulfillment for the STUDENT STUDY PROJECT in CHEMISTRY is a record
of original work investigated by us under the supervision of
Dr.K.RAVIKUMARDept.of chemistry Govt. Degree & P.G College,
Siddipet.

Further this is to state that the results embodied in this thesis have
not submitted to any other University or Institution for the award of
any degree or diploma.

NAME H.T.NO. GROUP

1.DHOVURI GURUDEV 6025-21-578-001 BSC[MCCs]

2.KESHABOINA MADHU 6025-21-578-003 BSC[MCCs]

3.VANAM AKHILA 6025-21-441-049 BSC[MPC]

4.VAJJA THIRUPATHI 6025-21-441-048 BSC[MPC]

5.VANMA BHARATH 6025-21-441-050 BSC[MPC]

6.VATTU PAVAN KUMAR 6025-21-441-052 BSC[MPC]

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ACKNOWLEDGEMENT

We extend my sincere thanks to my superiors he guide Dr.k.ravikumar for his

personal involvement in encouraging throughout the entire process of this work
and providing me with such stimulating and cordia atmosphere and
environment in which this project work carried out

we would like to express thanks to my teachers at the Department of U.G

CHEMISTRY, Government Degree College, Siddipet. Without whose active
support, advice and encouragement this work would not have been possible.

We thank all my friends for their cooperation, companionship and for being
available at all times when I needed them. Last but least I am grateful to my
beloved parents and my family members for their constant support, patience
and indulgence throughout the period of my studies.

DATE :

BY

MPC & MCCs STUDENTS

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 INDEX
S.NO. TOPIC
1. INTRODUCTION
2. ABSTRACT
3. GALVANIC CORROSION
4. MECHANISM OF RUSTING
5. RUSTING IN NON METALS
6. RUSTING IN GLASS
7. PREVENTIONS
8. EXPERIMENT (RUSTING OF IRON)
9. REQUIREMENT
10 PROCEDURE
11. OBSERVATION TABLE
12. CONCLUSION
13. RESULT
14. FACTOR PROMOTING RUSTING
15. PHOTOS OF PROJECT
16. METHOD OF PREVENTION

8
 ABSTRACT
Corrosion of iron occurs by rusting. Rust is a form of a hydrated
oxide(s) of iron formed as a result of chemical reactions of iron with
the atmosphere. This ‘atmospheric rust formation’ is a slow process.

Iron is a chemically ‘active’ element and possesses the tendency to

react with other reagents spontaneously. Artificially ‘rusting’ may be
induced readily by the use of suitable chemicals and little energy
input. Such reactions and methods help us to study the rusting
process in a vivid manner.

This technique relies on the main usage of acids and electricity.

Experiments were carried out to study the ionization of iron and its
subsequent oxidation into higher oxidation states with suitable
conditions and have been elaborated in this paper.

Corrosion of iron occurs by rusting. Rust is a form of a hydrated

oxide(s) of iron formed as a result of chemical reactions of iron with
the atmosphere. This 'atmospheric rust formation' is a slow process.

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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 Fe₂O, 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

RUSTING ON BRIDGE

10
PHOTOS OF THE EXPERIMENT

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AIM OF PROJECT :
TO STUDY THE RUSTING OF IRON IN
DIFFERENT PROCESS

OBJECTIVES :
Rusting of iron have several objectives:
❖ construct and analyze word and symbol equations for rusting,
❖ list the conditions which cause rusting to occur,
❖ interpret experimental results to describe the effects of different
conditions on rusting,
❖ describe the negative effects of rusting.

❖ Describe the conditions in which rusting occurs.

❖ Describe the methods of rust prevention

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 REVIEW OF LITERATURE

The first view taken of the atmospheric corrosion or rusting of iron was that it
was due to a simple process of oxidation. In 1888 Prof. Crum Brown suggested,
on the basis of experiments described by Crace Calvert in 1871, that the first
stage in the rusting of iron is the production, under the influence of carbonic
acid, of ferrous carbonate, which is subsequently converted, by atmospheric
oxygen in presence of moisture, into ferric hydroxide or rust.

In 1898, however, Prof. Dunstan, in a lecture delivered to the Royal Artillery

Institution, put forward another explanation; he considered that pure. oxygen
in presence of water is capable of attacking iron, giving rise to ferrous oxide and
hydrogen peroxide, part of the latter then converting the ferrous oxide into rust,
while the remainder directly attacks the iron, giving rise to a fresh quantity of
ferrous oxide, which in turn is again oxidized in a similar manner.

A detailed account of the experiments made in conjunction with Drs. Jowett

and Goulding, and of the theory, which may be called the hydrogen peroxide
theory of rusting, was published in October of last year. The theory was based on
certain phenomena of oxidation in which hydrogen peroxide was known to
be formed, and on the consideration that certain substances which
decomposed hydrogen peroxide were found to prevent the conversion of iron
into rust by damp air.

The older theory, that rusting was due to carbonic acid, was considered "quite
untenable. On the other hand, by removing the scrubbing arrangement by which
the air was freed from carbon dioxide, so as to permit the ingress of this gas with
the air, rusting commenced almost immediately, and in seventy-two hours the
whole of the surface of the metal was seen to be corroded, and a considerable
quantity of red rust was formed.

13
 Specimens of iron which had been exposed for several weeks to the action of
pure oxygen and water without rusting were exhibited by Dr. Moody at the recent
conversazione of the Royal Society.

It is also shown by Dr. Moody that while rust is being formed from iron under
natural conditions a large proportion of ferrous carbonate is produced; the
composition of rust in the course of formation is thus altogether out of harmony
with the hydrogen peroxide theory, since this theory postulates that twice as
much hydrogen peroxide is produced by the interaction of iron, oxygen, and
water as is necessary completely to oxidize the ferrous oxide to the ferric state.

The fact that certain compounds such as the alkalis, sodium nitrite, and
potassium ferrocyanide prevent rusting is due, not to their power of
decomposing hydrogen peroxide, but of interacting with carbon dioxide. Some
substances, such as potassium iodide, which destroy hydrogen peroxide do
not inhibit, but actually accelerate, the rusting of iron.

The facts recorded thus afford no basis for the assumption that iron can be
caused to rust by pure water and pure oxygen alone, and give a satisfactory
explanation of phenomena which were considered as being explicable only in the
light of the hydrogen peroxide hypothesis.

14
 GALVANIC CORROSION

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 the underlying

steel, when the tin coating is broken, the steel beneath is immediately attacked

preferentially.Build-up of voluminous Corrosion Products

Statue of Liberty-

15
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 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 of unaffected

connections, but it was regarded as a precautionary measure

16
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:

(1) 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) Fe+(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 H ions are obtained either
from water or from acidic substances (e.g. C) in water

H₂OH+OH- Or CO₂+H₂OH + HCO

At cathode: H+eH

The hydrogen atoms on the iron surface reduce dissolved oxygen.

17
4H+O →2H₂O

Therefore, the overall reaction at cathode of different electrochemical

cells may be written as,

4H++O+4e2H₂O

(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 –

Oxidation half reaction: Fe(s) → Fe2+(aq)+20]×2 (E=-0.441)

Reduction half reaction: 4H+O+4e2H₂O (E-1.231)

Overall cell reaction: 2Fe(s)+4H++O2Fe²+(aq)+2H2O (Ετ -1.671)

The ferrous ions are oxidised further by atmospheric oxygen to form

rust. 4Fe+(aq) + O2(g)+4H2O→ 2FeO +8H+ FeO + H2O Fe, OxHO

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.

18
GALVANIC CORROSION SIMULATOR

19
 RUSTING IN NON MEATALS

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, H2SO4.

CERAMICS-

Most of the ceramics 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

20
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.

21
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, UV-radiation can cause a breakdown

of the polymer chains.

3. Ozone: Attacks from ozone on unsaturated polymers (e.g. natural rubber)

under stress, causes characteristic cracks.

4.Water: 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.

5.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.
22
 PREVENTION OF RUSRING 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.

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.

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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.

APPARATUS –COUPLING ON RUSTING OF IRON

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 EQUIPMENTS REQUIRED

S.NO . EQUIPMENTS
1. Two Petri Dishes
2. Four test tube
3. Four iron nails beaker
4. Breaker
5. Sand papar
6. Wire gauge
7. Gelatin
8. Copper.zinc,and magnesium strips
9. Potassium ferricynaid solutions
10. phenolpthalein

phenolpthlene Potassium ferrocynaide solution

25
 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 nailin 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. 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.

ZINC STRIP WRAPPED AROUND ONE NAIL

26
 OBSERVATION TABLE

S.NO METAL PIAR PAIR COLOUR NAIL RUST OR

PATCH NOT
1. IRON –ZINC PINK NO
2. IRON – PINK NO
MAGNESIUM
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.

27
 RESULT :
❖ When iron comes in contact with moist air, rusting occurs. Iron

reacts with oxygen in the presence of water to form iron oxide.

Q. If you leave a piece of iron in the open for a few days, it

acquires a film of brownish substance, called rust.

❖ This is an oxidation reaction because the iron is losing

electrons and being oxidised to form iron(III) ions (Fe3+).

Oxygen, on the other hand, is gaining electrons and being

reduced to form oxide ions (O2-). Oxygen's role in the rusting

process is therefore to accept electrons from iron during the

oxidation reaction.

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GROUP MEMEBERS DURING EXPERIMENT

29
OBESERVING CORROSION DURING EXPERIMENT

30
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 (-
), 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

31
seawater. Sodium chloride deposited on atmospherically exposed
surfaces also acts as a hygroscopic material (i.e., it extracts moisture
from the air), which then increases the corrosion in non- immersed
areas.

Humidity: Humidity and time-of-wetness play a large role in

promoting and accelerating corrosion rates. Time-of-wetness refers to
the length of time an atmospherically exposed substrate 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 PREVENTION 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-
33
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.

34
REFERENCE:
CLASS 12TH CHEMISTRY
1.NCERT BOOKS
2. www.wikipedia.org
3. www.icbse.com
4. www.technopedia.com
5. www.slideshare.net

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THANK YOU

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