St.

Paul higher Secondary

School indore

Chemistry Investigatory
project on:
“Metal Coupling in Rusting of
Iron”

Submitted By: Submitted To:

Hardik Shukla Mr. Deshbir Singh

[1]
 Certificate
This is to certify that this Chemistry
Investigatory Project on the topic “Metal
Coupling in Rusting of Iron” is
successfully completed by Hardik Shukla
of class XII-E under the guidance of Mr.
Deshbir Singh during the academic year
2019-20 in particular fulfilment of the
curriculum of Central Board of Secondary
Education.

Teacher in charge: Principal:

External Examiner: Date:

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Contents

 Acknowledgement………….….…4
 Introduction……………………….….5
 Rusting of Iron………..…………...7
 Associated Reactions……....9
 Prevention…………………………....11
 Treatment………………………………15
 Metal Coupling………………..…..16
 Activity…..……………………………..17
 Conclusion………………..……….…19
 Bibliography……..……….…..…..20

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 Acknowledgement
I would like to thank our principal Father Sibi
Joseph and my school for giving me the golden
opportunity to do this wonderful project on the topic
“Metal coupling in Rusting of Iron” and providing
me with facilities required to do my project.
I would also like to express my special thanks of
gratitude to my Chemistry teacher Mr. Deshbir
Singh for helping me at all points of my struggles
through this project.

I would also like to thank my parents for having

faith in me which gave me immense confidence to
complete this project under the given time frame.

And at last but not the least, I would like to thank all
of my friends who helped me make this project a
success.

Thank you

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Introduction
Corrosion is a natural process which converts a refined
metal to a more chemically-stable form, such as
its oxide, hydroxide or sulphide. It is the gradual destruction
of metals by chemical or electrochemical reaction with their
environment. Corrosion engineering is the field dedicated to
controlling and stopping of corrosion.
OR: -
Corrosion means electrochemical oxidation of metal in reaction
with an oxidant such as oxygen or sulphates. Rusting, the
formation of iron oxides is a well-known example of
electrochemical corrosion. This type of damage typically
produces oxide(s) or salt(s) of the original metal.

Corrosion on metal (Rusting of Iron)

Rust is another name for iron oxide, which occurs when iron or
an alloy that contains iron, like steel, is exposed to oxygen and
moisture for a long period of time. Over time, the oxygen
combines with the metal at an atomic level, forming a new
compound called an oxide and weakening the bonds of the
metal itself.

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Rusting is the common term for corrosion of iron and its alloys,
such as steel. Many other metals undergo similar 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, which
generates green rust, is an example.
 Although rusting is generally a negative aspect of iron, a
particular form of rusting, known as "stable rust," causes
the object to have a thin coating of rust over the top, and if
kept in low relative humidity, makes the "stable" layer
protective to the iron below, but not to the extent of other
oxides, such as aluminium.

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 Rusting of Iron

Heavy rust on the links of a chain near the Golden Gate Bridge in San Francisco; it was
continuously exposed to moisture and salt spray, causing surface breakdown, cracking, and
flaking of the metal.

The main catalyst for the rusting process is water. Iron or steel
structures might appear to be solid, but water molecules can
penetrate the microscopic pits and cracks in any exposed
metal. The hydrogen atoms present in water molecules can
combine with other elements to form acids, which will
eventually cause more metal to be exposed. If chloride ions are
present, as in the case with saltwater, the corrosion is likely to
occur more quickly.
Meanwhile, the oxygen atoms combine with metallic atoms to
form the destructive oxide compound. As the atoms combine,
they weaken the metal, making the structure brittle and
crumbly.
Oxidation of iron
Although some people refer to rust generally as "oxidation",
that term is much more general; although rust forms when iron
undergoes oxidation, not all oxidation forms rust.
When impure (cast) iron is in contact with water, oxygen, other
strong oxidants, or acids, it rusts. If salt is present, for example
in seawater or salt spray, the iron tends to rust more quickly, as
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a result of electrochemical reactions. Iron metal is relatively
unaffected by pure water or by dry oxygen.
As with other metals, like aluminium, a tightly adhering oxide
coating, a passivation layer, protects the bulk iron from further
oxidation. The conversion of the passivating ferrous oxide layer
to rust results from the combined action of two agents, usually
oxygen and water.
Other degrading solutions are sulphur dioxide in water
and carbon dioxide in water. Under these corrosive
conditions, iron hydroxide species are formed. Unlike ferrous
oxides, the hydroxides do not adhere to the bulk metal. As they
form and flake off from the surface, fresh iron is exposed, and
the corrosion process continues until either all of the iron is
consumed or all of the oxygen, water, carbon dioxide, or
sulphur dioxide in the system are removed or consumed.
When iron rusts, the oxides take up more volume than the
original metal; this expansion can generate enormous forces,
damaging structures made with iron.

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 Associated Reactions
Rusting may be explained by an electrochemical mechanism.
In the presence of moist air containing dissolved oxygen or
carbon dioxide, the commercial iron behaves as if composed of
small electrical cells. At anode of cell, Iron passes into solution
as ferrous ions. The electron moves towards the cathode and
form hydroxyl ions. Under the influence of dissolved oxygen,
the ferrous ions and hydroxyl ions interact to form rust i.e.,
hydrated ferric oxide.

The reaction of the rusting of iron involves an increase in

the oxidation state of iron, accompanied by a loss of electrons.
Rust is mostly made up of two different oxides of iron that vary
in the oxidation state of the iron atom. These oxides are:

1. Iron(II) oxide or ferrous oxide. The oxidation state of iron

in this compound is +2 and its chemical formula is FeO.

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 2. Iron(III) oxide or ferric oxide, where the iron atom exhibits
an oxidation state of +3. The chemical formula of this
compound is Fe2O3.

Oxygen is a very good oxidizing agent whereas iron is a

reducing agent. Therefore, the iron atom readily gives up
electrons when exposed to oxygen. The chemical reaction is
given by:
Fe → Fe2+ + 2e–
The oxidation state of iron is further increased by the oxygen
atom when water is present.
4Fe2+ + O2 → 4Fe3+ + 2O2-
Now, the following acid-base reactions occur between the iron
cations and the water molecules.
Fe2+ + 2H2O ⇌ Fe(OH)2 + 2H+
Fe3+ + 3H2O ⇌ Fe(OH)3 + 3H+
The hydroxides of iron are also formed from the direct reaction
between the iron cations and hydroxide ions.
O2 + H2O + 4e– → 4OH–
Fe2+ + 2OH– → Fe(OH)2
Fe3+ + 3OH– → Fe(OH)3
The resulting hydroxides of iron now undergo dehydration to
yield the iron oxides that constitute rust. This process involves
many different chemical reactions, some of which are listed
below.

1. Fe(OH)2 ⇌ FeO + H2O

2. 4Fe(OH)2 + O2 + xH2O → 2Fe2O3.(x+4)H2O
3. Fe(OH)3 ⇌ FeO(OH) + H2O
4. FeO(OH) ⇌ Fe2O3 + H2O

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 Prevention

Cor-Ten is a special iron alloy that rusts, but still retains its structural integrity

Because of the widespread use and importance of iron and

steel products, the prevention or slowing of rust is the basis of
major economic activities in a number of specialized
technologies. A brief overview of methods is presented here.
Rust is permeable to air and water, therefore the interior
metallic iron beneath a rust layer continues to corrode. Rust
prevention thus requires coatings that preclude rust formation.

Galvanization:-

Galvanization consists of an application on the object to be

protected of a layer of metallic zinc by either hot-dip
galvanizing or electroplating. Zinc is traditionally used because
it is cheap, adheres well to steel, and provides cathodic
protection to the steel surface in case of damage of the zinc
layer. In more corrosive environments (such as salt
water), cadmium plating is preferred. Galvanization often fails
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at seams, holes, and joints where there are gaps in the coating.
In these cases, the coating still provides some partial cathodic
protection to iron, by acting as a galvanic anode and corroding
itself instead of the underlying protected metal. The protective
zinc layer is consumed by this action, and thus galvanization
provides protection only for a limited period of time.
Typical galvanization of steel products which are to subject to
normal day to day weathering in an outside environment
consists of a hot dipped 85 µm zinc coating. Under normal
weather conditions, this will deteriorate at a rate of 1 µm per
year, giving approximately 85 years of protection.

Interior rust in old galvanized iron water pipes can result in brown and black water.

Cathodic Protection:-

Cathodic protection is a
technique used to inhibit
corrosion on buried or
immersed structures by
supplying an electrical
charge that suppresses the
electrochemical reaction. If
correctly applied, corrosion
can be stopped completely.

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In its simplest form, it is achieved by attaching a sacrificial
anode, thereby making the iron or steel the cathode in the cell
formed. The sacrificial anode must be made from something
with a more negative electrode potential than the iron or steel,
commonly zinc, aluminium, or magnesium. The sacrificial
anode will eventually corrode away, ceasing its protective
action unless it is replaced in a timely manner.
Cathodic protection can also be provided by using a special-
purpose electrical device to appropriately induce an electric
charge.

Applied Coatings:-

Flaking paint, exposing a patch of surface rust on sheet metal

Rust formation can be controlled with coatings,

such as paint, lacquer, varnish, or wax
tapes that isolate the iron from the environment.
Large structures with enclosed box sections,
such as ships and modern automobiles, often
have a wax-based product (technically a "slushing oil") injected
into these sections. Such treatments usually also contain rust
inhibitors. Covering steel with concrete can provide some
protection to steel because of the alkaline pH environment at
the steel–concrete interface. However, rusting of steel in
concrete can still be a problem, as expanding rust can fracture
or slowly "explode" concrete from within.

As a closely related example, iron bars were used to reinforce

stonework of the Parthenon in Athens, Greece, but caused
extensive damage by rusting, swelling, and shattering
the marble components of the building.

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When only temporary protection is needed for storage or
transport, a thin layer of oil, grease, or a special mixture such
as Cosmoline can be applied to an iron surface. Such
treatments are extensively used when "mothballing" a steel
ship, automobile, or other equipment for long-term storage.

Special antiseize lubricant mixtures are available, and are

applied to metallic threads and other precision machined
surfaces to protect them from rust. These compounds usually
contain grease mixed with copper, zinc, or aluminium powder,
and other proprietary ingredients.

Bluing:-
Bluing is a technique that can provide limited resistance to
rusting for small steel items, such as firearms; for it to be
successful; water-displacing oil is rubbed onto the blued steel
and other steel.

Inhibitors:-
Corrosion inhibitors, such as gas-phase or volatile inhibitors
can be used to prevent corrosion inside sealed systems. They
are not effective when air circulation disperses them, and
brings in fresh oxygen and moisture.

Humidity control:-
Rust can be avoided by controlling the moisture in the
atmosphere. An example of this is the use of silica gel packets
to control humidity in equipment shipped by sea.

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 Treatment
Rust removal from small iron or steel objects by electrolysis can
be done in a home workshop using simple materials such as a
plastic bucket, tap water, lengths of rebar, washing soda, baling
wire, and a battery charger.
Rust may be treated with commercial products known as rust
converter which contain tannic acid or phosphoric acid which
combines with rust; removed with organic acids like citric
acid and vinegar or the stronger hydrochloric acid; or removed
with chelating agents as in some commercial formulations or
even a solution of molasses.

Rusted and pitted struts of the 70-year-old Nandu River Iron Bridge

Concentric rust patterns breaking through a painted surface

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 Metal Coupling

Hemera Technologies/PhotoObjects.net/Getty Images

Whenever two dissimilar metals are connected or placed

together, galvanic action takes place. Galvanic action is an
electrical phenomenon that causes a small current to flow. Over
time, this current flow causes oxygen to penetrate deep into
metals, causing corrosion. The end result is rust in ferrous
metals, and oxidation and degradation in non-ferrous metals. If
the metals are exposed to the weather, corrosion sets in
quicker, since water usually contains dissolved minerals which
are conductive. The only solutions to this problem are to use
the same kind of metals when coupling, or placing a non-
conductive block between dissimilar metals.

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 Activity
Aim :
To Investigate the effect of Metal Coupling on the Rusting
of Iron.

Apparatus :
a) Four Test-tubes
b) Two Petri Dishes
c) Four Iron nails
d) Beaker
e) Sand paper
f) Wire Gauge
g) Gelatine
h) Copper, Zinc and Magnesium Strips
i) Potassium ferricyanide solution
j) Phenolphthalein solution

Procedure :
(i) At first, clean the surface of Iron Nails with the help of sand
paper.

(ii) After that, wind zinc strip around one nail, a clean copper
wire around the second and a clean magnesium strip around
the third nail.

(iii) Preparation of Agar-Agar solution. Heat about three gram

of agar-agar in 100 ml of water taken in a beaker until solution
becomes clear. Add about 1 ml of 0.1 M potassium ferricyanide
solution, 1 ml of phenol-phthalein solution and stir the contents
well.
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(iv) Then put all the three and the fourth Iron nail in Petri dishes
so that they are not in contact with each other.

(v) Then fill the Petri dishes with the hot agar solution in such a
way that only lower half of the nails are covered with the liquids.

(vi) Keep the Petri dishes for one day.

(vii) The liquids set to a gel on cooling.

(viii) Observe the nails and record the observations.

Observations :
Two types of patches are observed around the rusted nails.
One is blue and other is pink. The blue patch is due to reaction
between ferrous ions and potassium ferricyanide to form
potassium ferro-ferricyanide KFe[Fe(CN)6] whereas pink patch
is due to the formation of hydroxyl ions which turns colourless
phenolphthalein to pink.

S. No. Metal Colour Nails

Pair of the Rust or
Patch not
1. Iron-Zinc Pink No
2. Iron- Blue Yes
Copper
3. Iron- Pink No
Magnesium
4. Iron-Nail Blue Yes

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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. But if
on other hand coupling of Iron with less
electropositive metals such as copper the
rusting is facilitated.

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 Bibliography
 Wikipedia.com
 XII class Chemistry NCERT Book
 XII class Chemistry Practical Book
 Photos from Google
 Slideshare.net

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