nger period. These approaches rely on the aluminium and zinc oxides reprotecting a once-scratched surface, rather than oxidizing as a sacrificial anode as in traditional galvanized coatings. In some cases, such as very aggressive environments or long design life, both zinc and a coating are applied to provide enhanced corrosion protection.
Typical galvanization of steel products which are to be subjected 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.
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. 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.
Coatings and painting
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.
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 is a technique that can provide limited resistance to rusting for small steel items, such as firearms; for it to be successful, a water-displacing oil is rubbed onto the blued steel and other steel.
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.
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 filled with an electrolyte consisting of washing soda dissolved in tap water, a length of rebar suspended vertically in the solution to act as an anode, another laid across the top of the bucket to act as a support for suspending the object, baling wire to suspend the object in the solution from the horizontal rebar, and a battery charger as a power source in which the positive terminal is clamped to the anode and the negative terminal is clamped to the object to be treated which becomes the cathode.
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 ac