Surface analysis by time-of-flight secondary ion mass spectrometry, X-ray photoelectron spectroscopy and scanning tunnelling microscopy has been applied to provide new insight on Mo effects on the composition and nanostructure of the passive films grown in sulfuric acid on well-controlled Fe–17Cr–14.5Ni–2.3Mo(100) austenitic stainless steel single crystal surfaces. A duplex hydroxylated oxide matrix, 1.8–1.9 nm thick, is formed with a strong partition between Cr(III) and Fe(III) in the inner and outer layers, respectively. Cr(III) is increasingly enriched by preferential iron oxide dissolution upon passivation and ageing. Ni, only present as oxide traces in the film, is enriched in the alloy underneath. Mo, mostly present as Mo(IV) in the Cr-rich inner layer prior to anodic polarisation, becomes increasingly enriched (up to 16% of cations) mostly as Mo(VI) in the Fe-rich outer layer of the passive film, with ageing promoting this effect. Metallic Mo is not significantly enriched below the passive film produced from the native oxide covered surface. Mo does not markedly impact the nanogranular morphology of the native oxide film nor its local thickness variations assigned to substrate site effects on Cr(III) enrichment. Site specific preferential passivation still takes place at the (native) oxide-covered step edges of the alloy surface, and transient dissolution remains preferentially located on the terraces. Nanostructures, possibly Mo-containing, and healing local depressions formed by transient dissolution during passivation, appear as a specific effect of the Mo presence. Another Mo effect, observed even after 20 h of passivation, is to prevent crystallisation at least in the Fe-rich outer part of the passive film where it is concentrated mostly as Mo(VI) (i.e. molybdate) species.

An approach preventing contact to ambient air during transfer from liquid environment for electrochemical treatment to UHV environment for surface analysis by X-Ray Photoelectron Spectroscopy and Time-of-Flight Secondary Ion Mass Spectrometry was applied to study the mechanisms of Cr and Mo enrichments in the passive oxide film formed on 316L austenitic stainless steel. Starting from the air-formed native oxide-covered surface, exposures were conducted in aqueous sulfuric acid solution first at open circuit potential and then under anodic polarization in the passive range. At open circuit potential the thickness of the bi-layered oxide film was observed to decrease and the enrichments of both Cr(III) and Mo, mostly Mo(VI), to markedly increase as well as the film hydroxylation. This is due to preferential dissolution of the Fe(III) oxide/hydroxide, not compensated by oxide growth in the absence of an electric field established by anodic polarization. Anodic polarization in the passive domain causes the bi-layered structure of the oxide film to re-grow by oxidation of iron, chromium and molybdenum, without impacting the Cr enrichment and only slightly mitigating the Mo enrichment. De-hydroxylation of the inner layer is also promoted upon anodic polarization. These results show that the treatment of the surface oxide film in acid solution at open circuit potential enhances Cr and Mo enrichments and promotes hydroxylation. Passivation by anodic polarization allows dehydroxylation, yielding more Cr oxide, without markedly affecting the Mo enrichment, also beneficial for the corrosion resistance.

Time of Flight Secondary Ion Mass Spectroscopy, X-Ray Photoelectron Spectroscopy, in situ Photo-Current Spectroscopy and electrochemical analysis were combined to characterize the physicochemical alterations induced by electrochemical passivation of the surface oxide film providing corrosion resistance to 316L stainless steel. The as-prepared surface is covered by a ∼2 nm thick, mixed (Cr(III)-Fe(III)) and bi-layered hydroxylated oxide. The inner layer is highly enriched in Cr(III) and the outer layer less so. Molybdenum is concentrated, mostly as Mo(VI), in the outer layer. Nickel is only present at trace level. These inner and outer layers have bandgap values of 3.0 and 2.6−2.7 eV, respectively, and the oxide film would behave as an insulator. Electrochemical passivation in sulfuric acid solution causes the preferential dissolution of Fe(III) resulting in the thickness decrease of the outer layer and its increased enrichment in Cr(III) and Mo(IV-VI). The further Cr(III) enrichment of the inner layer causes loss of photoactivity and improved corrosion protection with the anodic shift of the corrosion potential and the increase of the polarization resistance by a factor of ∼4. Aging in the passive state promotes the Cr enrichment in the inner barrier layer of the passive film.

Data recently obtained on model FeCrNi(Mo), 316 L stainless steel, and FeCrNiCo(Mo) passivated surfaces by advanced surface analysis and density functional theory modeling are comprehensively discussed to unravel the multiple effects that molybdenum might have at the nanometer and atomic scales to enhance the stability of passive films. The key role played on corrosion protection by the compositional and structural nanoscale defects of the passive film that originate from the pre-passivation mechanisms of the surface is considered. It is shown how Mo, enriched together with Cr in the nanometer-thick passive film, can combine several effects to enhance the resistance to Cl^--induced passivity breakdown. Enriched as Mo(VI) species in the outer exchange layer of the passive film, Mo impedes the deep penetration of Cl^- ions and limits their access to the inner barrier layer. Dispersed as Mo(IV) at the interface with the inner layer, Mo protects against the entry of Cl^- ions into the defect sites of the Cr(III) oxide barrier. Present as Mo(IV + δ) in the Fe-rich compositional nanoscale defects self-generated by the local failure of Cr supply upon initial formation of the barrier layer, Mo enhances the selective dissolution of iron and its replacement by chromium and molybdenum. By impeding the formation of O vacancies, Mo also increases the resistance against chloride entry in the oxide matrix, thereby curing these the Fe-rich weak sites against Cl^--induced passivity breakdown.

Stainless steels are widely used as metal components owing to self-protection in aggressive environments, provided by an extremely thin surface oxide film enriched in chromium oxide. Yet, despite decades of research, the mechanisms distributing the chromium enrichment at small length scale are poorly understood, although it may cause loss of stability and local failure of the corrosion resistance. Here, we apply high resolution surface analysis to investigate at small time and length scales the nucleation and growth mechanisms of the surface oxide on a model stainless steel. Starting from an oxide-free surface, we report the direct observation of the oxide nucleation and local oxidation of chromium, which governs the nanoscale heterogeneity of the growing surface oxide by chromium pumping from the atomic terraces to the steps for preferential Cr(III) oxide nucleation and subsequently by segregation from the atomic planes below to grow the Cr(III) layer incompletely saturating the stainless steel surface. This work provides new insight on corrosion chemistry, by evidencing local chemical and structural defects self-generated at the nanoscale by the building process of the protective oxide barrier, and affecting the passive film stability.

Passivation mechanisms and the effects of controlled pre-oxidation, by exposure to oxygen at ultra-low pressure, on Cr and Mo surface enrichments were investigated on polycrystalline AISI 316L stainless steel surfaces with direct transfer between surface preparation and analysis by X-ray photoelectron spectroscopy and electrochemistry. Exposure to sulfuric acid at open circuit potential causes preferential dissolution of oxidized iron species, which promotes Cr³⁺ and Mo^4+/6+ enrichments. Anodic passivation forces oxide film re-growth and Cr³⁺ dehydroxylation with no loss of Mo^4+/6+ pre-enrichment. Ultra-low pressure pre-oxidation promotes Mo^4+/6+ enrichment in the exchange outer hydroxide layer of the passive film, with no Mo⁰ depletion in the modified alloy region underneath the oxide film at open circuit potential, and under anodic passivation. Mo^4+/6+ enrichment improves protectiveness against transient active dissolution during the active/passive transition.