I. Historical Development of Rust Preventive Oil Formulations
1. Early Stage (19th Century to Early 20th Century): Mineral Oils Combined with Basic Additives
The origins of rust preventive oil can be traced back to the late 19th century, driven by the rise of the metalworking and machinery industries during the Industrial Revolution. As metal corrosion became increasingly problematic, early rust preventive formulations used mineral oils as the base, combined with small amounts of natural fats (e.g., lanolin) or waxes as rust inhibitors. These early formulas formed thick films (over 50 microns), were dust-prone, difficult to clean, offered limited rust protection, and were highly sensitive to environmental humidity and temperature. As a result, they were mainly used for short-term protection of simple metal components.
2. Technological Breakthrough (Mid to Late 20th Century): Synthetic Additives and Performance Optimization
The mid-20th century marked significant advancements in rust preventive technology, driven by progress in the chemical industry. Synthetic rust inhibitors such as petroleum sulfonates and carboxylic acid soaps were introduced, along with solvent dilution techniques that led to the development of solvent-based and emulsifiable rust preventive oils.
For example, during World War II, the U.S. developed hard-film rust preventive oils (e.g., P-20) for military equipment that formed quick-drying protective layers via volatile solvents, significantly improving corrosion resistance. In the 1970s, companies like Shell and ExxonMobil introduced multifunctional oils combining lubrication and corrosion protection by incorporating organic rust inhibitors such as sulfonates and imidazolines.
By the 1980s, Japan’s JIS K 2246 standard helped reduce the film thickness of NP-series rust preventive oils to 5–10 microns, effectively lowering application costs. Meanwhile, vapor corrosion inhibitor (VCI) technology began to emerge, using volatile corrosion inhibitors to protect metal surfaces in enclosed spaces.
In China, the rust preventive oil industry was initially developed with Soviet technical assistance. Early products were mainly mechanical oils blended with rust inhibitors based on the ГОСТ standards, forming films thicker than 30 microns, which only met basic protective requirements. In 1972, the domestically developed F20-1 rust preventive oil was documented in the report “Summary of F20-1 Rust Preventive Oil Trials”, marking a milestone in independent R&D. In 1983, the China Petroleum Research Institute improved the F20-1 formulation by adding zinc naphthenate and benzotriazole to address copper alloy corrosion. That same year, the Anti-Rust Lubrication Subcommittee of the China Surface Engineering Association was established in Wuhan, and later restructured in 1992 into the Corrosion Protection Committee.
In 1988, the Rust Prevention Subcommittee under the National Technical Committee for Standardization of Metal and Non-metallic Coatings (CSBTS/TC57) was founded to develop and revise technical standards. This led to the establishment of industry benchmarks such as JB/T 4050.1-1999 “Technical Requirements for Vapor Phase Rust Preventive Oil”, greatly accelerating the industry’s development.
3. Environmental and Functional Integration Era (Since the 21st Century): Green Formulations and Multi-Functional Design
Since the 21st century, increasingly stringent environmental regulations and the growing diversity of industrial needs have pushed rust preventive oil formulations toward eco-friendly and high-performance solutions. The use of heavy metal additives such as barium salts has come under scrutiny. Plant-based oils (e.g., soybean oil, castor oil derivatives) have gradually replaced a portion of mineral oils, reducing environmental impact.
At the same time, combining corrosion protection with lubrication and cleaning functions has become a new trend. Dual-purpose rust preventive and lubricating oils now not only serve storage needs but can also be used directly in operational machinery.
Western countries have taken the lead in the development of synthetic additives and green technologies. Innovations such as nano-enhanced protective films and biodegradable formulations have yielded significant results. For instance, in 2015, Cortec Corporation in the U.S. launched the VpCI-649 rust preventive oil containing nano zinc oxide, achieving a film thickness of just 0.8 microns with salt spray resistance exceeding 30 days.
Although China entered this field later, it has rapidly built a comprehensive industrial chain through technology transfer and independent innovation. The booming domestic additive industry has strongly supported the progress of the rust preventive sector. Many Chinese brands have successfully replaced foreign products in end-user applications. Through advances in materials science, process integration, and standards alignment, domestic companies are heavily investing in technological capabilities and are poised to become major global players in the near future.
II. Trends in Rust Preventive Oil Formulation Technologies
1. Environmental Friendliness and Low Toxicity
With global carbon reduction initiatives accelerating, the demand for environmentally friendly rust preventive oils is surging. For instance, barium-free rust preventive oils are already being used. Water-based and solvent-free formulations, which reduce volatile organic compound (VOC) emissions, have become mainstream solutions. Both the EU REACH regulation and China’s 13th Five-Year Plan for Energy Conservation and Emission Reduction have established clear requirements in this regard.
However, many rust preventive products on the market still use D40 or high-aromatic solvents as diluents—these pose notable environmental and health risks. In contrast, D60, D80, refined kerosene, and isoparaffinic hydrocarbons are currently considered safer and more sustainable alternatives.
As for the future of solvent-diluted rust preventive oils and barium sulfonate-based additives, the question remains: will policy or market forces take the lead? Time will tell.
Ruqinba also produces various products used in anti-rust oil, especially dodecenylsuccinic acid and oleoyl sarcosine octadecyl ammonium salt.
2. Functional Integration
Rust preventive oils are evolving from single-purpose protection products to multifunctional formulations. “Three-in-one” formulations that combine rust prevention, lubrication, and cleaning functions are gaining popularity, as they help reduce the number and cost of lubricants used in industrial processes.
Additionally, the emergence of new energy industries—such as lithium battery manufacturing—has created demand for specialized oils with high-temperature resistance and electrolyte corrosion protection tailored for components like battery casings.
3. Intelligent and Customized Formulations
With the integration of big data and artificial intelligence, rust preventive oil formulation is entering a new era of precision. Manufacturers can now dynamically adjust additive ratios based on users’ operating conditions (e.g., humidity, metal type), enabling “one formulation per facility” customization. For example, one company simulated micro-environments on metal surfaces to optimize rust inhibitor adsorption, extending protection periods by up to 30%.
Moreover, the industry must rethink the widespread obsession with salt spray test hours. Is endlessly pursuing ultra-high salt spray resistance truly cost-effective? The answer deserves serious consideration.
4. Collaborative Innovation Across the Supply Chain
Synergies between rust preventive oil producers, upstream petrochemical suppliers, and downstream manufacturing sectors are becoming increasingly important. For example, joint development of high-performance rust inhibitors with additive manufacturers; co-design of rust preventive oils for galvanized steel with steel producers; and collaboration with automotive OEMs to test long-lasting rust protection systems—all help form a closed-loop innovation model that strengthens the industry as a whole.
III. Conclusion
From mineral oil-based formulations to synthetic additives, and from single-purpose protection to eco-friendly multifunctional solutions, the evolution of rust preventive oil formulation has always progressed in step with industrial demands and technological advancements.
Looking ahead, as emerging industries such as advanced materials and new energy continue to rise, rust preventive oils will face increasing performance requirements and more complex application scenarios. Only through continuous innovation and cross-disciplinary integration can this traditional industry move toward higher value-added, sustainable development.
