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The reason for this is because rust is weaker than iron and decreases strength. Iron rust flakes off and has holes in it that allow water and air to further corrode deeper layers of iron (like a pile of potato chips). Aluminium, stainless steel and other metals form a complete continuous layer and prevent further corrosion. It is not because of reduced surface area if anything the surface area is increased (especially with iron)

AnswerI believe its because the overall surface area of the bar is decreased, hence the structural integrity of the bar is compromised. Strangely enough, when aluminum rusts the aluminum oxide on the surface of the metal increases resistance to further corrosion without reducing the surface area.

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