METALS
AND
RUSTS
GROUP 5
• Railey Visquera
• Camila Rose Pernecita
• Jiliana Taruc
• Red Francisco
• Christopher Fernandez
• John Mark Suarez
• Arron Josh Sevilla
• Melvin Corre
• Julius Mark Centeno
• Delmar Somono
Metals and Rusts
• Metals can rust when they come into contact
with oxygen and moisture. Rust is a form of
corrosion that primarily affects iron and steel.
It occurs when iron reacts with oxygen in the
presence of water or moisture to form iron
oxide, which is the reddish-brown substance
we commonly refer to as rust.
O Rust weakens the metal and can eventually lead to
structural damage if not addressed. Preventing rust
often involves protective coatings, such as paint or
galvanization, to create a barrier between the metal
and its environment.
O Regular maintenance and keeping metal objects
dry can also help prevent rust.
Metallurgy
O is defined as a process that is used for the extraction of
metals in their pure form. The compounds of metals
mixed with soil, limestone, sand, and rocks are known
as minerals.
O Metals are commercially extracted from minerals at
low cost and minimum effort.
O These minerals are known as ores. A substance which
is added to the charge in the furnace to remove the
gangue (impurities) is known as flux. Metallurgy deals
with the process of purification of metals and the
formation of alloys.
Metallography
O is the study of the microstructure of all types of
metallic alloys. It can be more precisely defined as
the scientific discipline of observing and
determining the chemical and atomic structure and
spatial distribution of the grains, constituents,
inclusions or phases in metallic alloys.
COMPOSITION OF METALS
O Generally, all metals can be classified into groups such as
ferrous, non-ferrous and alloys.
The ferrous group of metals is composed mainly of iron.
They may have small amounts of other metals or other
elements added such as carbon, manganese, nickel,
chromium, silicon, titanium, tungsten etc., to give the
required properties.
Non-Ferrous are metals which do not contain any iron as
a component. The common pure metals are: aluminum,
copper, lead, zinc, tin, silver and gold.
Alloy is a new metal which is formed by mixing two or
more metals and sometimes other elements together.
VARIATION OF METALS
1. STEEL - is an iron alloy enriched with around 1%
carbon and it is generally free of the impurities and
residues that can otherwise be found in iron.
O Additionally, steel has a rather high strength to weight
ratio compared to other types of metals, which enables
the manufacturing of small yet strong steel parts. With
over 3500 different grades and almost 2 billion tons of
steel manufactured globally each year, steel is the most
commonly used metal in the world.
O Alloy steel - is made by combining elements such as
chromium, manganese, nickel, tungsten, or vanadium
with iron. Each of the alloying elements brings
different properties to the mix, thus making the alloy
steel highly customizable.
O Stainless steel - is a highly corrosion-resistant alloy
steel that consists of iron, carbon, significant amounts
of chromium and residues of other metals. It is a
versatile material widely applied in many households.
From kitchen utensils to tables, sinks, and other
furniture, stainless steel is perfect for the
manufacturing of anything that comes into contact
with food because it doesn’t rust easily.
Carbon steel- is an alloy made of iron and carbon,
sometimes with residues of other elements. It is commonly
categorized into three groups (low, medium, and high carbon
steel) based on the amount of carbon the alloy contains. The
more carbon is used to manufacture steel, the harder the alloy
will be.
Tool Steel - due to its hardness, tool steel is used for the
manufacturing of cutting, drilling, and other shock-resistant
tools. The hardness comes from alloying iron with elements
such as cobalt, molybdenum, tungsten, or vanadium. Tool
steel has a wide variety of applications, including
construction, shipbuilding and automotive industries. It is
primarily used to machine and make changes to different
kinds of steel.
2. IRON
O With around 5% of the Earth’s crust and as the 6th most
common element in the universe, iron is a highly abundant
and immensely popular metal. Unalloyed iron is an unstable
element that easily reacts with the oxygen from the air and
forms iron oxide. In order to make it more stable, it is
commonly alloyed with other elements to create steel.
3. ALUMINUM
O is a highly durable, light-weight and corrosion-resistant
metal derived from its ore bauxite. First made in the 19th
century, aluminum found wide-spread use due to its
machinability, electrical conductivity, and inability to
magnetize. It is the most common non-ferrous metal on
Earth, known for its malleability and ability to form alloys
with almost all other metals.
4. ZINC
O Process of Galvanizing Zinc is a common metal with a low
melting point. Because it flows smoothly in its melted form, it is
easy to cast and recycle. The end product is quite strong and has
low electrochemical potential. Zinc is used to coat and protect
other metals, as well as to prevent rusting in galvanized steel.
5. BRONZE
O Bronze Church Bells Bronze is made by alloying copper and
tin, and often small amounts of elements such as aluminum,
manganese, silicon or phosphorus. As the first human-made
alloy, bronze is incredibly historically significant – thus the
“Bronze Age.” Even though it is brittle, bronze is a hard
element known to resist fatigue that doesn’t bend or crack. Due
to its high corrosion resistance and solid thermal and electrical
conductivity, it is used for the manufacturing of electrical
connectors, church bells, ship parts and reflectors.
Procedures in Examination
O The examination of metals and rusts typically involves a
combination of physical, chemical, and microscopic techniques to
assess their composition, integrity, and corrosion. Here are some
common procedures used:
1. Visual Inspection - examine the metal surface visually for signs
of corrosion, such as rust, pitting, or discoloration. Note the overall
condition, including cracks, scratches, or other surface defects.
2. Surface Cleaning - remove any loose rust, dirt, or contaminants
using a wire brush, sandpaper, or chemical cleaning agents.
3. Weight Loss Analysis - weigh the metal sample before and after
exposure to corrosive conditions to determine the extent of corrosion.
This is often done in controlled corrosion testing environments.
4. Microscopic Examination - use a microscope to
inspect the surface and cross-section of the metal to
identify corrosion products, cracks, or other
structural issues.
5. Chemical Analysis - perform chemical tests, such
as acid digestion or spectroscopy, to analyze the
composition of the metal and corrosion products.
6. Corrosion Testing - subject the metal to
accelerated corrosion tests to assess its resistance to
corrosion under specific conditions, such as salt
spray testing or immersion in corrosive solutions.
7. Electrochemical Techniques - use
electrochemical methods like potentiostatic and
galvanostatic testing to determine corrosion rates,
corrosion potentials, and polarization curves.
8. X-ray Diffraction (XRD) - employ XRD to
analyze the crystalline structure of rust and corrosion
products, helping to identify their composition.
9. Scanning Electron Microscopy (SEM) - utilize
SEM to examine the surface morphology and
microstructure of the metal and rust, providing
detailed information about the corrosion process.
10. Material Testing - conduct mechanical tests (e.g.,
tensile, hardness, impact) to assess the mechanical
properties of the metal and how corrosion affects its
strength.
11. Corrosion Product Analysis - collect and analyze
rust or corrosion products to understand their
composition, which can provide insights into the
corrosion mechanisms.
12. Non-destructive Testing (NDT) - employ
techniques like ultrasonic testing or radiographic
inspection to assess the integrity of metal structures
without causing damage.
O These procedures are essential for
evaluating the condition of metals
and rusts, helping to determine their
suitability for various applications
and informing corrosion prevention
and mitigation strategies. The
specific methods chosen depend on
the nature of the material and the
objectives of the examination.
Use of magnetic particle
O They can be easily concentrated by the use of an
external magnetic field and transferred from one
solution to another, which is why magnetic particles
are widely used to isolate and concentrate various
biomaterials such as bacteria, viruses, proteins, toxins,
hormones, DNA, RNA, and even whole cells.
Methods of Electro Acid Etching
O Electrochemical etching, also known as electro acid
etching or electrolytic etching, is a process used to create
detailed and precise markings or patterns on metal
surfaces. Here are the basic steps involved in this method:
1. Preparation - you'll need a piece of metal to etch,
typically made of stainless steel or other conductive metals.
Clean the surface thoroughly to remove any contaminants
like oils, grease, or dirt.
2. Design - create or acquire the design or pattern you want
to etch onto the metal. This design is usually transferred onto
a stencil or mask made of a material resistant to the etching
process, such as vinyl or special etching resist films.
3. Stencil Application - apply the stencil or mask onto the
metal surface, ensuring it adheres tightly and covers the areas
you want to protect from etching. This leaves only the desired
design exposed.
4. Electrolyte Solution - prepare an electrolyte solution. This
is typically a mixture of water and an electrolyte chemical,
such as salt or sodium carbonate (soda ash). The electrolyte
facilitates the flow of electricity between the metal and the
electrode.
5. Electrode Setup - you need two electrodes, one connected
to the positive terminal (anode) and the other to the negative
terminal (cathode) of a power source (usually a DC power
supply). The metal piece to be etched is connected to the
positive terminal (anode), while a separate conductive
electrode (usually made of graphite or stainless steel) is
connected to the negative terminal (cathode).
6. Etching Process - immerse the metal and the cathode
electrode in the electrolyte solution without letting them
touch each other. When you pass a low-voltage direct current
(DC) through the setup, metal ions from the metal surface will
dissolve and react with the electrolyte, creating the etched
pattern. The metal ions migrate from the anode (the metal
piece) to the cathode electrode.
7. Control and Timing - the depth and precision of the
etching can be controlled by adjusting factors such as voltage,
current, and the duration of the etching process. Longer
exposure or higher voltage will result in deeper etching.
8. Rinse and Finish - once the desired depth and detail are
achieved, remove the metal piece from the electrolyte
solution, rinse it thoroughly to remove any remaining
electrolyte, and carefully remove the stencil or mask.
9. Cleaning and Final Touches - clean the etched metal
surface to remove any residues, and you may apply additional
finishing techniques, such as polishing or coating, to enhance
the appearance and protection of the etched design.
NOTE:
Safety precautions, such as wearing protective gloves and eye protection,
should be observed when working with chemicals and electricity during
the electrochemical etching process.
Consideration in Specimen
When examining specimens of metal and rust, consider the following key
aspects
1. Metal Identification - identify the type of metal in the specimen. This
is crucial because different metals have varying susceptibility to rust and
corrosion.
2. Rust Identification - determine the type of rust present. Common rust
types include red rust (Fe2O3) and black rust (Fe3O4). The type of rust can
provide insights into the corrosion process.
3. Corrosion Rate - assess the rate of corrosion. Is the corrosion
progressing slowly or rapidly? This can help gauge the severity of the
issue.
4. Environmental Conditions - understand the environmental factors
that contributed to corrosion. Consider factors like humidity, temperature,
exposure to moisture, salt, chemicals, or pollutants.
5. Microstructural Analysis - examine the microstructure of
the metal and rust using microscopy. This can reveal details
about the corrosion mechanism, grain boundaries, and
potential defects in the metal.
6. Chemical Analysis - analyze the chemical composition of
both the metal and the rust. This can help identify corrosion
by-products and provide insights into the corrosion process.
7. Historical Context - investigate the history of the
specimen, including its age and previous uses. This historical
context can offer clues about the corrosion history and
potential causes.
8. Preventive Measures - based on your analysis, consider
preventive measures to protect the metal from further
corrosion. This may involve applying protective coatings or
changing the environmental conditions.
9. Material Testing - perform mechanical and material testing to
assess the structural integrity of the metal. Corrosion can weaken
metals, and understanding their condition is crucial.
10. Documentation - maintain thorough records of your
observations, analyses, and findings. Proper documentation is
essential for future reference and decision-making.
11. Safety - prioritize safety when handling corroded materials.
Use appropriate protective gear and follow safety protocols to
minimize health risks.
O By carefully considering these factors, you can gain a
comprehensive understanding of the metal and rust specimen,
assess the extent of corrosion, and make informed decisions
regarding preservation, restoration, or corrosion prevention
measures.
Usefulness in Investigation
O Investigating rust on metals is essential for various reasons,
including:
1. Corrosion Prevention - understanding rust formation
helps in developing strategies to prevent corrosion,
which can save resources and extend the lifespan of
metal structures.
2. Material Integrity - rust inspection ensures the
structural integrity of metal components, such as bridges,
pipelines, and vehicles, reducing the risk of failures.
3. Forensic Analysis - in criminal Investigations,
analyzing rust on weapons or tools can provide
valuable evidence, linking objects to crime scenes or
suspects.
4. Environmental Impact - studying rust formation
in industrial settings helps mitigate the
environmental impact of corrosion and improve
waste management.
5. Historical Preservation - rust analysis aids in
preserving historical artifacts, ensuring they remain
intact for future generations.
THANKYOU!