KISSAN INTERNATIONAL

SCHOOL AND Jr.

COLLEGE OF SCIENCE

STUDY OF THE EFFECT OF METAL COUPLING ON THE

RUSTING OF IRON

PRESENTED BY :
NAME : KUSHAGRA SHARMA
CLASS : XII- CBSE
SUBJECT : CHEMISTRY

SUBJECT TEACHER : HARISH BHOR SIR

PRINCIPAL NAME : MANOJ RATHOR

YEAR : 2024-2025
 STATEMENT OF PURPOSE

The purpose of this project is to investigate the effect of metal coupling on the rusting of iron, a
significant phenomenon with vast implications in both industrial and everyday contexts.
Corrosion is a natural process that compromises the integrity of metals, leading to considerable
economic and safety concerns. Understanding the underlying mechanisms of rusting and how
different metals influence this process is crucial for developing effective prevention strategies.

Through this project, I aim to explore how coupling iron with various metals, such as zinc and
magnesium, affects its susceptibility to rusting. The investigation will delve into the
electrochemical principles governing corrosion, highlighting the roles of anodes and cathodes in
the rusting process. By analyzing the interactions between metals and environmental factors, I
hope to contribute valuable insights into corrosion prevention methods, which are essential in
preserving infrastructure and extending the lifespan of metal products.

This study not only emphasizes theoretical understanding but also encourages critical thinking
and problem-solving skills. It provides an opportunity to apply scientific concepts to real-world
scenarios, reinforcing my passion for chemistry and its practical applications. Ultimately, I aspire
to present findings that can inform future research and practical measures to combat corrosion,
promoting safety and sustainability in various industries.
 ACKNOWLEDGEMENT

I would like to extend my heartfelt gratitude to everyone who has supported me throughout the
completion of my Chemistry project. This project has not only deepened my understanding of
chemical concepts but has also enhanced my appreciation of their practical applications in real-
world scenarios.
Firstly, I am extremely grateful to my Chemistry teacher, for their invaluable guidance and
encouragement throughout the course of this project. Their expertise and patience in explaining
complex concepts, as well as their constructive feedback, have played a crucial role in shaping
the direction and success of this project.
I would also like to express my sincere thanks to my school, for providing access to the
laboratory and necessary resources to carry out my experiments. The assistance from the lab
technicians, who helped me with the setup and handling of chemicals and equipment, was
essential in ensuring the safety and accuracy of my work.
A special thank you goes to my parents, who have always been a source of unwavering support
and motivation. Their constant encouragement has inspired me to stay focused and put in my
best effort at every stage of this project.
Lastly, I would like to acknowledge the Central Board of Secondary Education (CBSE) and the
National Council of Educational Research and Training (NCERT) for creating a comprehensive
and practical curriculum that emphasizes the importance of applying theoretical knowledge to
real-life situations. This project has been an excellent opportunity to apply the concepts I’ve
learned in class and explore their significance in practical chemistry.
I am truly thankful for the opportunity to work on this project, which has enriched my
understanding of Chemistry. The knowledge and skills I have gained through this experience will
undoubtedly benefit me in my future studies.
Thank you.
 ACTION PLAN

Objective: To effectively conduct research and compile the theoretical framework for the
chemistry project on the effect of metal coupling on the rusting of iron.

Research Preparation:

● Gather relevant books, articles, and online resources that discuss corrosion, metal
coupling, and rusting.

● Identify key concepts and terms that are crucial for understanding the project’s scope.

Theoretical Study:

● Focus on understanding the mechanisms of rusting and the electrochemical principles

involved.

● Explore the differences between electropositive and less electropositive metals and their
impact on rusting.

Note-taking:

● Take organized notes on important theories and findings, ensuring to highlight key points
that support the project’s aim.

● Summarize each source in a concise manner to facilitate easier reference later.

Outline Development:

● Develop a structured outline for the project report, including sections such as
introduction, literature review, discussion, and conclusion.

● Ensure the outline logically presents the information, leading the reader through the
concepts effectively.

Drafting the Report:

● Start drafting the project report based on the outline, integrating the research findings and
personal reflections.

● Focus on clarity and coherence in presenting the information, ensuring that the scientific
concepts are easily understood.

Visual Aids Creation:

● Design charts, diagrams, or illustrations that effectively convey the processes of rusting
and the effects of metal coupling.

● Ensure that visual aids complement the written content, enhancing understanding.

Review and Edit:

● Set aside time to review the draft, checking for clarity, grammar, and adherence to the
project guidelines.
 ● Make necessary revisions to improve the flow and ensure accuracy in the scientific
content.

Final Touches:

● Prepare the final version of the report, ensuring all citations and references are formatted
correctly.

● Print or save the project in the required format, ready for submission.
 INDEX

● Introduction

● Mechanism of Corrosion of metal

● Electrochemical Mechanism (rusting)

● Methods of Prevention of Corrosion

● Economic Effect

● Aim of this Project

● Requirements

● Procedure

● Observation

● Conclusion

● Bibliography
 INTRODUCTION

Corrosion :

Corrosion is the gradual destruction of metals due to their interaction with environmental factors
such as oxygen, moisture, and acids. It is an electrochemical process in which a metal undergoes
oxidation, resulting in the formation of stable compounds like oxides or hydroxides. The most
familiar form of corrosion is the rusting of iron, which involves the conversion of iron into iron
oxide in the presence of air and moisture. Corrosion leads to the weakening and degradation of
metal structures, affecting their strength and utility.

Introduction to Corrosion :

Metal corrosion is the most common form of corrosion. The corrosion occurs at the surface of
the metal in forms chemical or electrochemical reactions. This process significantly reduces the
strength, plasticity, toughness and other mechanical properties of the metallic material. However,
because of the metal and its alloys is still the most important pipe and structure materials, the
cost of corrosion grows significantly with the growth of industries. Corrosion is a universal
problem faced by industries and individuals alike, impacting various aspects of daily life, from
infrastructure to household appliances. It is a spontaneous and inevitable process driven by the
thermodynamic tendency of metals to return to their more stable forms (such as oxides or
sulfides), from which they were originally extracted. Thus many scientists focus on the research
of corrosion control in order to reduce the cost of replacing the rusting metal material.
Nowadays, there are mainly two corrosion control method that are very popular in the world.
One is impressed current and another is sacrificial anode cathode protection system. In this
project , we will focus on the mechanism and application of the sacrificial anode cathode
protection system.

MECHANISM OF CORROSION
Corrosion of metals, particularly iron, is an electrochemical process that involves the creation of
a galvanic cell. The mechanism can be understood using the example of rusting of iron:

Anodic Reaction (Oxidation):

At certain spots on the surface of iron, iron atoms lose electrons and are oxidized to form iron
ions (Fe²⁺). These spots act as the anode.

Fe → Fe2+ +2e−

Here, iron atoms lose electrons (undergo oxidation) and enter the solution as iron ions (Fe²⁺).

Cathodic Reaction (Reduction):

The released electrons from the anodic areas travel through the metal to other areas, where they
reduce oxygen present in water (moisture) to form hydroxide ions (OH⁻). This occurs at the
cathode.

O2 + 4e- + 2H2O → 4OH−

Oxygen from the atmosphere, dissolved in water, is reduced at the cathodic sites.

The Electrochemical Mechanism : Rusting

The Fe²⁺ ions produced at the anodic site combine with OH⁻ ions from the cathodic reaction to
form iron(II) hydroxide:

Fe2+ + 2OH −→ Fe(OH)2

Iron(II) hydroxide is further oxidized by atmospheric oxygen to form iron(III) hydroxide, which
eventually dehydrates to form hydrated iron oxide (rust):

4Fe(OH)2 + O2 + 2H2O→4Fe(OH)3

Fe(OH)3 → Fe2O3⋅nH2O

This iron oxide (rust) is porous and flakes off easily, exposing more metal to the environment,
allowing the corrosion process to continue.

Conditions Required for Corrosion:

 Presence of Moisture: Water is an essential component for the electrochemical reactions

involved in corrosion. Even a small amount of moisture from the air can trigger rusting in iron.

 Presence of Oxygen: Oxygen plays a key role in the reduction process, forming hydroxide
ions that combine with metal ions to form rust.

 Electrolyte: The presence of dissolved salts or acids can increase the conductivity of water,
accelerating the corrosion process. This is why metals corrode faster in salty or acidic
environments.
 METHODS OF PREVENTION OF CORROSION

Various treatments are used to slow corrosion damage to metallic objects which are exposed to
the weather, salt water, acids, or other hostile environments. Some unprotected metallic alloys
are extremely vulnerable to corrosion, such as those used in neodymium magnets, which
can spall or crumble into powder even in dry, temperature-stable indoor environments unless
properly treated.

Applied coatings

Plating, painting, and the application of enamel are the most common anti-corrosion treatments.
They work by providing a barrier of corrosion-resistant material between the damaging
environment and the structural material. Aside from cosmetic and manufacturing issues, there
may be tradeoffs in mechanical flexibility versus resistance to abrasion and high temperature.
Platings usually fail only in small sections, but if the plating is more noble than the substrate (for
example, chromium on steel), a galvanic couple will cause any exposed area to corrode much
more rapidly than an unplated surface would. For this reason, it is often wise to plate with active
metal such as zinc or cadmium. If the zinc coating is not thick enough the surface soon becomes
unsightly with rusting obvious. The design life is directly related to the metal coating thickness.

Galvanized Surface
Anodization

Aluminium alloys often undergo a surface treatment. Electrochemical conditions in the bath are
carefully adjusted so that uniform pores, several nanometers wide, appear in the metal's oxide
film. These pores allow the oxide to grow much thicker than passivating conditions would allow.
At the end of the treatment, the pores are allowed to seal, forming a harder-than-usual surface
layer. If this coating is scratched, normal passivation processes take over to protect the damaged
area.

Anodizing is very resilient to weathering and corrosion, so it is commonly used for building
facades and other areas where the surface will come into regular contact with the elements.
While being resilient, it must be cleaned frequently. If left without cleaning, panel edge
staining will naturally occur. Anodization is the process of converting an anode into cathode by
bringing a more active anode in contact with it.

This climbing descender is anodized

with a yellow finish.

Cathodic protection :

Cathodic protection (CP) is a technique to control the corrosion of a metal surface by making it
the cathode of an electrochemical cell. Cathodic protection systems are most commonly used to
protect steel pipelines and tanks; steel pier piles, ships, and offshore oil platforms.
 AIM OF THIS PROJECT

In this project the aim is to investigate effect of the metals coupling on the rusting of iron. Metal
coupling affects the rusting of iron. Metal coupling affects the rusting of iron. If the nail is
coupled with a more electropositive metal like zinc, magnesium or aluminium rusting is
prevented but if on the other hand, it is coupled with less electro-positive metals like copped, the
rusting is facilitated.

Requirements :

1) Two Petri dishes

2) Four test tube

3) Four iron nails
4) Beaker

5) Sand Paper
6) Wire gauge
7) Gelatin
8) Copper, zinc and magnesium strips

9) Potassium Ferricyanide solutions

10) Phenolphthalein
Procedure :

1) At first we have to clean the surface of iron nails with the help of sand paper.

2) After that we have to wind zinc strip around one nail, a clean copper wire around the
second and clean magnesium strip around the third nail. Then to put all these three and a
fourth nail in Petri dishes so that they are not in contact with each other.

3) Then to fill the Petri dishes with hot agar agar solution in such a way that only lower half
of the nails are covered with the liquids.

4) Keep the covered Petri dishes for a day or so.

5) The liquids set to a gel on cooling. Two types of patches are observed around the rusted
nail, one is blue and the other is pink. Blue patch is due to the formation of potassium
ferroferricyanide where pink patch is due to the formation of hydroxyl ions which turns
colorless phenolphthalein to pink.

Observation :

S no. Metal Pair Colour of the patch Nail rusts or not

1 Iron-Zinc White Mild corrosion

2 Iron-Magnesium Pink Mild corrosion

3 Iron-Copper Blue Rusts

Conclusion :

It is clear from the observation that coupling of iron with more electropositive metals such as
zinc and magnesium resists corrosion and rusting of iron. Coupling of iron with less
electropositive metals such as copper increases rusting.
 STUDENT REFLECTIONS

Completing the project on the effect of metal coupling on the rusting of iron has been a highly
enriching experience that has significantly deepened my understanding of chemistry, particularly
in the context of real-world applications. At the beginning of this project, I had a basic
understanding of rusting and corrosion, but conducting experiments allowed me to explore these
concepts in much greater depth.

The hands-on nature of the project enhanced my practical laboratory skills, such as setting up
experiments, measuring variables, and recording observations accurately. I learned how to
manage time effectively while coordinating tasks with my teammates, which was essential for
completing the project on schedule. This collaboration taught me the value of teamwork; sharing
ideas and solutions helped us to overcome challenges and deepen our collective understanding of
the topic.

Additionally, I gained insights into the scientific method—hypothesizing, experimenting,

analyzing data, and drawing conclusions. Observing the differing effects of metal coupling on
rusting provided a tangible context for theoretical concepts, making the learning process more
engaging and relevant. For instance, seeing how zinc and magnesium acted as sacrificial anodes
to protect iron was fascinating and demonstrated the practical applications of electrochemical
principles.

In summary, this project has not only enriched my academic knowledge but also fostered
personal growth. I have become more curious, resourceful, and collaborative, traits that I will
carry forward in my future studies. I am grateful for the opportunity to delve into this important
topic, and I look forward to applying what I have learned in my future academic and professional
endeavors.
 BIBLIOGRAPHY

For the project, I have referred to the following sources :

1) Comprehensive (Practical chemistry – XII)

2) Internet – www.wikipedia.com

3) NCERT Chemistry Textbooks