Analytical techniques including TEM, SEM–EDX, FIB, Auger electron spectroscopy and XRD were employed to detail the fouling phenomenology for a heated stainless steel wire immersed in atmospheric bottoms fraction crude oil, exposed for 1–1400 min. A key microstructural observation is the transformation of the wire’s as-received near-surface textured austenitic grain structure into a micron scale (e.g. ∼10 μm at 1400 min) highly porous inner-sulfide/chromium oxide bilayer composite.