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When steel "rusts," it is because of corrosion. NACE International (formerly National Association of Corrosion Engineers) generally defines corrosion as the deterioration of a substance (usually a metal) due to a reaction with it's environment. For corrosion to occur, four things have to be present:

-an anode (point where corrosion occurs)

-a cathode (protected area)

-an electrolyte (i.e; water with ionic content)

-a metallic pathway

Corrosion can be prevented by eliminating any of these four elements. A corrosion cell is best illustrated by a galvanic corrosion cell where two different metals are in physical contact (creating a difference in electropotential) and exposed to an electrolyte. A classic example would be a zinc or magnesium anode protecting carbon steel.

However, corrosion or "rust" can still occur on an unprotected sheet of a single metal, such as carbon steel, due to variations within the steel or steel surface. Differences in electropotential within a single metal can be created by many things, including steel composition, mil scale, metalworking, discontinuities in coatings or other protective films, welding, etc. In this case, the area that corrodes is acting as the anode (often manifest as pitting), the areas not corroding (protected) would be the cathode, the electrolyte could simply be the moisture and salts within the surrounding air, and the metal itself would act as the metallic pathway for current to flow between anodic and cathodic sites.

A few things that you can do to prevent rust are:

* Apply a protective coating (i.e; paint)

* Select an alternate material that is corrosion resistant

* Utilize an inhibitor

* Install cathodic protection (impressed current or galvanic) for applications where the metal is immersed, buried in soil, or encased in concrete.

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