THE RISK OF RUST AND THE ROLE OF RUST PREVENTIVES

Rust has plagued almost every industry since the beginning of the industrial revolution by impairing the functionality and stability of machinery made of iron.

What is Rust?

Rust is a reddish-brown iron oxide that manifests when bare iron undergoes a reaction with oxygen in the catalytic presence of water or moisture in the air. Rust comprises hydrous iron (III) oxides and iron (III) oxide-hydroxide.

Rust and its Types

There are different kinds of rust, all of which appear different depending upon the factors that led to their manifestation. 

Determining the type of rust people have on their machinery, valuable insights can be acquired about the root causes of its formation and approaches to prevent rust manifestation in the future. Here are the four dominant forms of rust:

● Red Rust

Hydrated oxide-Fe2O3•H2O

Rust from Iron (III) oxides with prolonged exposure to high oxygen and moisture.

● Yellow Rust

Iron oxide-hydroxide FeO(OH)H2O

Rust from Iron (III) oxides that had prolonged exposure to moisture.

● Brown Rust

Oxide Fe2O3

Rust from Iron (III) oxides that had exposure to surplus oxygen and minimal moisture.

● Black Rust

Iron (II) oxide-Fe3O4

Rust from Iron (III) oxides that got exposed to limited oxygen and low moisture.

The Difference Between Corrosion and Rusting

Most people often interchangeably use corrosion and rust to represent the oxidation of metals; however, there exists a subtle difference between rust and corrosion.
● Corrosion is the process by which both metals and nonmetals deteriorate due to constant oxidation. Corrosion does not stay restricted to metals, but almost every material that is sensitive to oxidation.

● Rusting is the oxidation of iron when exposed to oxygen and moisture. Rusting manifests on the surfaces of iron and its alloys and is found in different forms.

Industrial Damages Associated With Rust

While rust might appear like a deterrent that might not require immediate attention, it can be incredibly hazardous if left uncatered, such as:

● The collapse of bridges

● The potential risk of reactor meltdowns

● Rusted vessels that store nuclear waste can develop leaks.

● Closing of several oil pipelines.

● Rusted military jets and ships being retired prematurely.

Rust Prevention

Some general preventive measures that people can follow to protect their iron machines from rusting without breaking the bank include:

1. Use alloys

2. Apply preventive oils

3. Cover it with paint

4. Galvanization

5. Powder Coating

Rust Prevention - Effective and Economical

One of the ideal approaches to preventing rust is to keep moisture from coming in contact with the iron component, using oil preventives, or coating it with another metal.Here are some of the best ways that people can implement to safeguard their iron machines and parts from rusting without having to spend a fortune on half-measures that fall apart:

1. Use Alloys - One of the best methods of completely ridding machinery of rust is to replace components and machines made of iron with alloys like stainless steel. Stainless steel works for most applications and can be economical in the long run.

2. Oil Preventives - Coating machinery and parts with oil are one of the most effective ways of preventing rust and slowing it down due to its property of inhibiting moisture from reaching the iron. Rust preventives are applied to the iron component during a semi-finished or finished stage.

3. Proper Storage - It is advisable to store metal parts in a low-moisture space or inside a temperature and a humidity-controlled atmosphere to retard the pace of rust. Using desiccant drying agents can also be beneficial.

4. Galvanization - Galvanization involves coating iron or steel in zinc to prevent the rusting of the inner metal. Zinc corrodes at a slower pace than iron or steel, making it remarkably effective against rust.

5. VCI Packaging - Vapor Corrosion Inhibitors (VCI) is a chemical compound that safeguards iron by emitting rust eradicating vapours. This process happens in an enclosed air space which prevents rusting when it gets infused into packaging materials.

6. Blueing - This process involves creating a layer of magnetite over the iron surface to ward off rust. The metal requires regular oiling to ensure that rust resistance is maintained, and it often turns blue or black during the process.

Oil Preventives - Overview and Types

Rust preventive oils are created to lubricate and safeguard metals, including iron, from atmospheric corrosion. They are an effective way to prevent rusting of iron.How Do They Work?Rust preventive oils comprise polar substances that enable them to stick to and film the surface of the metal to inhibit corrosion. Rust preventive oils can be used between operations or for a final anti-corrosion shield before dispatch.

Rust preventive oils are used extensively in the automotive sector to boost the performance of cooling systems, brake systems, and other components. Besides protecting the metal from rusting, they also provide lubrication for the smooth functioning of the machinery.

Types of Oil Preventives

Here are the different rust preventive oil types that are widely used in modern-day industries to safeguard metals from corrosion:
        ● Solvent-Based Rust Preventive Oil

Solvent-based rust preventive oils ward off the rust by creating a protective coating on the surface of the metal to prevent it from coming in contact with water or oxygen-rich air.

People can directly apply it to the metal surface with no need for dilution. These inhibitors have a high surface tension which keeps moisture away and displaces the lingering moisture content. 

        ● Water-Based Preventive Oil

Water-based preventive oils are more affordable than solvent-based inhibitors. They reduce the metal's oxidation susceptibility and are easily applicable to any metal surface. Some ways through which people can apply this preventive oil is using spray or immersion techniques.

According to rust preventive oil manufacturers in India, water-based agents are harmless for the environment in terms of pollution and disposal.

        ● High Flash Rust Preventive Oil

A high-flash rust preventive coating dries almost immediately, which helps manufacturers get rid of oily surfaces that often invite dust and pollutants. High flash rust preventive oil safeguards the metal for up to 6 months under shelter. 

Factors to Consider When Selecting a Preventive Oil

When in the market to pick up a rust preventive oil, people must make the appropriate choice as per the quality and the brand of the oil.

This decision must be made with utmost considerations because factors such as moisture, breakage of RP oil film, and acid fumes can trigger rusting at an accelerated pace.

Here are the criteria that one must account for before deciding upon any product -

● Increased operational costs

● Increased rework and rejections

● Environmental concerns

● Premature changeover or high waste

● Export regulations

Considering that the rust preventive film is susceptible to breakage, the individual must ensure certain quality parameters are met before deciding which product they should pick.

There are primarily three fundamental criteria to account for:

Criteria 1: Product Quality Parameters

A decent rust preventive oil must meet the following quality parameters under all conditions:

● Water displacement

● Fingerprint suppression

● Acid fume protection

● Film retention

● Temperature stability

● Compatibility of fluid with engine oils and transmissions oils

Criteria 2: Optimizing Operations Cost

Besides offering superior quality and excellent results, the rust preventive oil must also provide decent ROI by optimizing operations expenditures:

● Thin-film layer, fit to final part with no additional operation

● Optimize assembly operations and enhance quality

● Compatible with engine oil, gear oils, and paint.

● Minimized consumption

Criteria 3: Safety Compliance

One of the most crucial factors to consider before purchasing a rust preventive oil is to ensure that it complies with all regulations and is safe to use for the technicians:

● Must not be hazardous 

● Barium free

● Must not contain VOCs (Volatile Organic Compounds)

● Compliant with the EPA regulations

When such critical parameters come into play, it becomes pivotal that people opt for a leading global brand that offers high-grade industrial lubricants and rust preventive oils, such as Castrol.

Final Words

Castrol is a global oil corporation that offers industrial and automotive lubricants by presenting an extensive range of lubricants, rust preventive oils, greases, and other products for lubrication purposes.
Castrol offers one of the best rust preventive oils in the market, Rustilo. Castrol's rust preventive oil, Rustilo, has a robust mode of operation which involves:

Rustilo eliminates previous process liquids, aggressively repels water, and leaves minimal residue.

Rustilo offers a wide variety of products that provide unique benefits and are suitable for people with different requirements. Its new generation Rustilo range comprises:

Besides these, Rustilo also has shelves full of a conventional range under the category of waxy film, oily film, and dewatering solvent. Moreover, you also get Castrol's on-site support after purchasing our product, regardless of your location. 

How does your industry tackle rust problems, and what ways do you implement to deal with them? Feel free to write to us; we would be pleased to learn all about it.