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. 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. Only iron or alloys that contain iron can rust, but other metals can corrode in similar ways.
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 sodium is present, as is 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.
Some pieces of iron or steel are thick enough to maintain their integrity even if iron oxide forms on the surface. The thinner the metal, the better the chance that rusting will occur. Placing a steel wool pad in water and exposing it to air will cause rusting to begin almost immediately because the steel filaments are so thin. Eventually, the individual iron bonds will be destroyed, and the entire pad will disintegrate.
Rust formation cannot be stopped easily, but metals can be treated to resist the most damaging effects. Some are protected by water-resistant paints, preventative coatings or other chemical barriers, such as oil. It also is possible for one to reduce the chances of rust forming by using a dehumidifier or desiccant to help remove moisture from the air, but this usually is effective only in relatively small areas.
Steel is often galvanized to prevent iron oxide from forming; this process usually involves a very thin layer of zinc being applied to the surface. Another process, called plating, can be used to add a layer of zinc, tin or chrome to the metal. Cathodic protection involves using an electrical charge to suppress or prevent the chemical reaction that causes rust from occurring.
By Michael Pollick