The Detroit Post
Saturday, 16 October, 2021

How Rust Spreads

author
Earl Hamilton
• Wednesday, 23 December, 2020
• 11 min read

| Eastwood Blog Posted: November 21, 2018, By: Matt In the automotive restoration world we refer to rust like it is a “cancer” or infection that spreads in metal. Rust ALWAYS starts when bare metal is exposed to oxygen and water.

reclaimed rust hetfield james
(Source: www.simonandschuster.com)

Contents

On most vehicles it is a design flaw in which a part is constantly exposed to water or corrosive materials and it breaks down the factory paint or coating. Once the coating is compromised moisture and oxygen can get in and start the rust process.

This means even something as small as a rip in seam sealer or a water drain being clogged in a car door can expedite the rusting process. The metal needs to be exposed to water and oxygen, so you can have an area that is extremely rusty and an inch next to it is completely fine because the paint or coating wasn’t sacrificed.

Rust is the common name for what is scientifically known as iron oxide, a form of corrosion that occurs when iron (or one of its alloys, such as steel) reacts with oxygen and there is water (or heavy air moisture) present. Other metals have oxidation processes as well, but they do so differently and the result is not commonly considered rust.

Instead, the process of iron oxidization occurs independently based on the conditions surrounding a particular piece of metal. This means that if one part of the piece is exposed to water, oxygen, and electrolytes but the rust of the piece is kept clean and dry, the protected metal will not rest at the rate of the wet metal.

If the zinc coating on a piece of galvanized steel is scratched or scraped away, the exposed area will be vulnerable to rusting. Rust is one of the most common problems professionals in the automotive repair industry encounter.

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(Source: www.gardeningknowhow.com)

It can quickly spread on the metal parts of your car and leave unsightly marks. Rust will become visible on the metal surface within a few minutes to several years, depending on environmental and metallurgical factors.

Rust can spread quickly, provided it is exposed to water, salt, and oxygen in the environment. In general, rust can spread slowly if there is little or no exposure to water or moisture and oxygen.

Rust can start developing on the surface of your car, provided the factory paint is broken. If it is not addressed early, rust can weaken the metal and destroy the integrity and functionality of a vehicle.

To reduce the cost of production, automobile companies prefer working with alloy metals. Since alloy metal is prone to rust, there are several ways to treat and protect it from corrosion.

Rust is a chemical process that occurs when metal, water, and oxygen mix. Iron, a popular raw material for vehicle assembly, is highly vulnerable to rusting compared to other metals.

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(Source: www.saffronmarigold.com)

However, a pure alloy is less tensile, flexible, and easy to mold when manufacturing vehicles. Manufacturers combine the ore with other metals to form an alloy to make iron flexible for automobile production.

Automobile companies prefer coating metal with a chemical that slows down rusting. Surface rusting forms when the protective layer that coats metal is compromised.

Vehicle companies use chromium and nickel to make car parts because of their slow rate of corrosion. Repeated heating of steel alloy refines the metal but also makes it more prone to scale rusting.

Penetrative rusting happens when metal is exposed to corrosive elements for a prolonged period. At this point, the damage on the car is irreversible and total metal replacement is required.

As a solution, vehicle manufacturers are opting to mix aluminum and magnesium with iron. Magnesium and aluminum are ideal for vehicle assembly because they are more resistant to penetrative rusting.

spreads cookie simplylakita dough thickness onto spread sheet
(Source: www.simplylakita.com)

Cars are built with a protective layer on the chassis to prevent the spread of rust or corrosion. However, the protective coating is compromised when salt and road grime accumulates on tires.

Always wash under your car thoroughly, including the tires to stop rust from spreading into the interior of the vehicle. Check the drain holes on the doors and rocker panel to ensure water does not accumulate in them.

Waxing your car adds a protective layer to the paint, which minimizes the chances of rusting. First, mask the area you are working on with poly sheeting to protect the rest of the car from paint spills.

In addition, sand around the affected area to create more space for feathering edges. Apply an epoxy primer to create a firm bonding surface on metal.

Apply two or three layers of lacquer filler primer and leave the surface to dry. For a full guide on how to remove surface rust from a car check this article.

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(Source: worldofcherie.blogspot.com)

The bubbles of rust have flaked away at this stage, leaving behind gaping holes on the metal. Alternatively, you may weld patch panels on the affected areas to stop rusting and restore the car’s aesthetics.

If you do not trust your DIY fixing skills, then take your vehicle to a repair shop. Vehicle repair shops have advanced equipment for testing the integrity of the car after fixing rusted metal.

The presence of salt in a solution can cause rust to spread in metals more quickly. Unlike a biological infection, the process of iron oxidization or rust occurs independently on the condition of a piece of metal’s surrounding.

This only means that if one part of the metal is exposed to electrolytes, oxygen, or water, it is prone to rust. Even the portion of the metal that was kept clean and dry will not rest due to the rate of the exposed part.

Iron alloys have dissimilar corrosion rates as influenced by their respective structure. Feelable Protective Coatings are becoming more and more popular due to their ease of use and rust -inhibiting factors.

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(Source: www.prabhat-india.in)

I was just wondering if there are any effective treatments to stop the rust from spreading. I don't think I want (read: can't afford right now) to pay to take it to a body shop to have it sanded, primed, and repainted.

(Very interesting and depressing to find rust bubbles that are covered with the car's original paint.) I have had a 67 ford galaxies for about 6 years and when I bought it is had a some surface rust on the frame.

I painted just about every part I could get to under the car with a brush and 5 years later none of it has come back through or chipped off. I also did several spots on the body including the 1/4 panels(rear fender).

Sickle, Cruiser uses exactly that sacrificial anode method to protect their out-drives from corrosion during use in salt water. As for buying online, the site Roger linked to have that option on the navigation bar to the left.

EDIT: Oops, misread your post about buying online. I would expect that any good auto store would be able to order it for you if they didn't have it in stock.

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(Source: ask.extension.org)

Rust usually appears as a red, brown or orange flaking or pitting of the metal surface. Rust is formed when oxygen comes into sustained contact with iron in a process called oxidation.

Copper, which is commonly used in household wiring, has a bright, reddish color, although it can turn green when exposed to air. For example, the corrosion of copper and its alloys, bronze and brass, produces a green layer called patina or verdigris.

Prime rust conditions occur when iron is regularly exposed to saltwater and humid air. One gram of tetanospasmin can kill 6,000,000 average-size men, making it approximately 1,600,000 times more potent than King Cobra venom.

Tetanus is extremely rare, amounting to an incidence of 0.15 cases per 1,000,000 people in the U.S., according to the Centers for Disease Control. However, people who have not received recent vaccinations, such as older adults, are at increased risk for tetanus.

A study of canine tetanus revealed that many cases originated from cuts caused by sharp spike lets of grass known as oxtails. Any cuts caused by an object made dirty by soil, regardless of whether it is rusted or even metal, should be treated as a potential source of Clostridium retain.

cedar orange trees gunk ask oregon
(Source: ask.extension.org)

Rust has considerably less mechanical strength than its originating metal and it will not adhere but will gradually flake off, weakening the structure. It also has a greater volume than iron, and its buildup will force apart adjacent parts, a phenomenon called rust -smacking.” Through this process, rust can make a structure more vulnerable to collapse from weather, impact, or even gravity.

If this situation is not detected and remedied, the deterioration will persist and cause serious structural problems. Manufacturing defects that increase the likelihood of moisture penetration include insufficient cover (less than 1-1/2 inches of concrete), insufficient air bubbles to trap moisture, cement that was mixed with too much water, and inadequate time allowed for the concrete to cure before loads were applied.

For more information, consult Internal’s article Detecting Corrosion in Concrete-Encased Steel ; water pipes. Much rust -damaged metal roofs have been painted over without repair, leading to moisture intrusion into the house.

Decaying leaves and pine needles create an acidic solution that will eat away at the galvanized coating on metal chimney covers, leaving them exposed to rusting from rain and melting ice and snow. The weakened metal will permit the entry of water inside the chimney, causing further rusting.

Observe the rusted chimney pictured at right, courtesy of Internal member John Gromkoski; fuel oil tanks. Steel fences are highly susceptible to rust because they are exposed to rain and snow and their maintenance is often neglected by homeowners.

agefotostock
(Source: www.agefotostock.com)

Coatings and paint can form a barrier between iron or steel and environmental moisture. Flushing oil is a common wax-based product applied to metal to minimize corrosion.

One downside of its use is that older weathered-steel formulations can stain nearby sidewalks and buildings where rainwater has drained from the steel, although manufacturers have since remedied this defect. Rusting is slowed significantly when the relative humidity is brought below 50%, which may be accomplished through the use of a dehumidifier or silica desiccant, or by other means.

Houses in coastal areas or near roads salted by snowplows are at heightened risk. Common hygroscopic contaminants, such as zinc chloride and sodium nitrate, will suck moisture from the air and trap it on the metal surface to accelerate rusting.

Rust removal techniques do exist, however, and Internal inspectors may recommend the following methods to clients in situations where their implementation is cost- and labor-effective: Paints or rust inhibition primers may then be applied to protect the metal surface against future corrosion.

Rust can be dissolved from iron and steel components by submerging them in vats of phosphoric, sulfuric, hydrochloric or italic acid. Larger or permanently installed metal cannot be treated in this way because items must first be removed and transported to a shop.

lime spreading field truck farm preview dreamstime
(Source: www.dreamstime.com)

Rust can be powdered or flaked off by flame cleaning, which involves the use of an intensely hot oxyacetylene torch. In summary, rust is the product of an electrochemical reaction between carbon dioxide, oxygen and iron.

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Sources
1 www.tcghomes.com - https://www.tcghomes.com/
2 mallardrealestate.com - http://mallardrealestate.com/
3 jonescompanyappraisers.com - https://jonescompanyappraisers.com/
4 www.summitlifestyle.org - http://www.summitlifestyle.org/our-story/
5 www.homes.com - https://www.homes.com/wichita-ks/homes-for-rent/
6 www.hirschirealtors.com - https://www.hirschirealtors.com/market-share-report
7 realestate.idahopress.com - https://realestate.idahopress.com/realtors/show/7/scott_latham.html