From the 100-odd elements that are known to exist in this universe, millions of combinations can be made to form the thousands of materials that surround us every day. Most of it is carbon and silicone based--the building blocks of life--but the air we breath contains oxygen (O), nitrogen (N) and hydrogen (H), along with a host of probably hazardous chemicals you shouldn't be inhaling. Also in the air is moisture (H2O); we call it humidity, but it is really just water vapor swirling around up there.
Down here on the ground, the bodies of our beloved VWs are made of steel, which is derived from iron (Fe), the fourth most abundant element on Earth (which is arguable). Slight traces of carbon is added to iron to form common steel (I mean slight being roughly around 0.1 percent), and the carbon content in iron has a significant impact on the characteristics of the final alloy. There are around 3000 types of steel. For example (and to contrast "regular" car steel), an alloy of 17 percent chromium and eight percent nickel is used to form stainless steel.
In the beginning, approximately 4.6 billion years ago, when Earth was being formed, there was hydrogen, carbon, nitrogen, oxygen and iron floating around in space. These molecules were formed at the Big Bang, and iron started to soak up the oxygen. This prevented the carbon and the nitrogen from reacting with oxygen. If oxygen had combined with these two elements, carbon dioxide and nitrogen oxide would have been formed, and these are both hazardous gases for human beings. Instead, iron reacted with oxygen and turned into rust. This gave carbon and nitrogen a chance, which both reacted with hydrogen and formed methane and ammonia. Subsequently, these two compounds eventually formed DNA, and here we are.
At any rate, our VWs are really just iron, an element that reacts extremely well with oxygen, which is why iron in your diet helps promote good circulation. For cars, however, iron always seeks out oxygen. If your car is kept in a completely moisture-free environment, that's fine, bond away. However, it's probably not, and that's when the really damaging rust happens.
You see, whether you want it to or not, chemical reactions happen all the time, as each element in the periodic table meets other elements, like a big singles' bar. Sometimes the elements get together and sometimes they don't. When it comes to Mr. Iron and Miss Oxygen, they always hook up. Because of the baggage Miss Oxygen carries into the relationship, by way of the moisture in the air, unprotected Mr. Iron will always corrode, or as we know it, rust. As the picture above shows you, the results aren't pretty.
Found on the package tray...
Found on the package tray of my '71 Super was this Swiss-cheese delight. These holes were made with a slight poke of my finger.
It's like this: The oxygen and moisture combine with iron to create a hydrated ferric oxide--Fe2O3 x H2O--on the surface of the metal (surface rust can be easily removed and isn't much of a threat). It's a two step chemical process. I didn't like chemistry when I was forced to take it, but some of you may, so here it is:
Step One: Two parts of Iron (Fe) + Three parts of Oxygen (O) = Iron oxide, Fe2O3, which is technically rust, but in a realitively harmless form.
Step Two: Fe2O3 + H2O, water = hydrated iron oxide, Fe2O3 x H2O, or rust, which is harmful in every way.
Because the ferric oxide that is created is bulky and porous, it allows more oxygen access to the iron below, causing additional rust. If allowed to continue, the oxygen and water will completely convert the remaining iron to ferric oxide or solid rust, which is weak and flaky, hence big holes in metal.
How do you stop rust? It's easy. Keep oxygen away from your car. No oxygen, no chemical reaction, no problem. However, since oxygen makes up roughly 21 percent of the air we breath, and there's tons of moisture in that air, it is nearly impossible.
Generally, the only way to seal the surface is to mechanically or chemically remove all the rust before the surface can be sealed again. If any rust remains, and paint is applied over the surface, enough moisture and oxygen will travel through the paint molecules to start the rusting process again (i.e. paint bubbles).
There are four main methods for dealing with rusty metal: mechanical removal, specialty paints, acids and chemical converters. With the exception of chemical conversion, many procedures for removing rust involve toxic chemicals or require special equipment.
Mechanical Removal-One of the most common methods of removing rust is by the use of grinders, wire brushes, sandpaper and sandblasting. For minor rust, sandpaper will effectively remove surface rust, while sandblasting will take care of the rest.
Special Paints-A few paints on the market claim the ability to encapsulate rust. They have chemical structures that have very tight molecules that will not allow moisture or oxygen to reach the rusted metal surface.
Acids-Acids (specifically phosphoric acid) dissolve the rust and leave behind a thin oxide coating on the surface. It is important rinse off the metal before the acid begins to attack the metal. This is similar to paint stripping. In this process, the metal is dipped in large tanks of caustic soda (no, not Pepsi!). After the paint is dissolved, the metal is removed and put in another tank of alkaline solution and the rust removed electrolytically.
Chemical Conversion-Blacksmiths were the first to discover this when they coated their tools with oil and then heated them in an oven. This process, known as magnetite, creates a very hard coating, protecting it from rust. Because magnetite is chemically inert, it does not react with oxygen or water.
There you have it, the four-letter word doesn't sound so bad after you say it a few times with the understanding that there are ways of not only fighting it but preventing it.