An AFM and XPS study of corrosion caused by micro-liquid of dilute sulfuric acid on stainless steel

Micro-liquid of dilute sulfuric acid deposited on SUS304 steel surface were observed with the ac non-contact mode of an atomic force microscopy (AFM), and the detail of the corrosion process caused by them was investigated with the contact mode of the AFM, X-ray photoelectron spectroscopy (XPS) and wavelength dispersive X-ray spectroscopy (WDXS). As a result, even not applying bias voltages between the tip of the cantilever and the specimen, micro-liquid of sulfuric acid can be successfully imaged using the ac non-contact mode of AFM. Two shapes of micro-acid, i.e., micro-droplets and micro-films, were found to co-exist on the specimen surface. On areas covered by micro-films of acid, only small corrosion product particles appeared and no corrosion pits were found. Beneath micro-droplets, corrosion reaction continue to produce pits until they were all consumed to form a corrosion product (mainly iron oxides) with almost the same shape with the droplet. The total corrosion reaction time was speculated to be between 690 and 1500 ks. The corrosion product formed from micro-droplets was believed to be a process of accumulating small corrosion product particles from the liquid/substrate interface to the surface of the formerly produced corrosion product. The XPS and WDXS analysis also supports the above results. # 2004 Elsevier B.V. All rights reserved.