They are different in how they look and different in the circumstances that led to their formation. At Armor Protective Packaging, we recognize that identifying the type of rust is the first step in identifying a solution to prevent it. We like to compare rust to an iceberg (see Rust Iceberg graphic below) — it’s not what you can see above the surface of the water that is most destructive, but rather it’s what you can’t see that can do the most harm. The same is true of rust and corrosion, often it’s the things that aren’t visible or that are less obvious that result in the greatest damage.
Visually, rust appears in a color spectrum that can range from yellow to red to black. Conditions that lead to rust formation also run the spectrum, but most can be attributed to one of three general factors
Whether it is the cleaning process, the metal fabrication process such as cold working, heat treating or machining or the handling process, this aspect of producing a metal part is a primary contributor of corrosion. Much of what is seen in terms of corrosion problems, happen inside the manufacturing plant before it’s even packaged. With so many variables inside of a manufacturing setting, maintaining tight control of your processes is critical to preventing rust.
The type of materials used to package metal parts is important. Acidic materials such as corrugated and non-treated paper can actually trap or hold moisture and cause corrosion. Sometimes in a companies’ desire to fix a corrosion problem they add more packaging, which can have a reverse effect by contributing even more to the rust problem.
While the weather (temperature and humidity) can certainly be the most obvious environmental factor, other things such as contaminants in the air pose equal areas of concern.
Identifying the type of rust you are experiencing can provide valuable insight as to what may be its root cause. To help, ARMOR developed a roster of the types of rust that are frequently found in the manufacturing or outbound shipping setting — complete with photos and the key attributes and contributors of each type of rust.
Rust from Iron (III) oxides forms due to high oxygen and water exposure resulting in red rust.
Rust from Iron (III) oxides that is a very soluble iron oxide results in yellow rust.
Rust from Iron (III) oxides with high oxygen and low moisture results in brown rust.
Rust from Iron (III) oxides with limited oxygen and low moisture results in black rust.
