Materials Transactions, Vol. 46, No. 7 (2005) pp. 1636 to 1645 Special Issue on Medical, Healthcare, Sport and Leisure Materials #2005 The Japan Institute of Metals OVERVIEW Antibacterial Metals —A Viable Solution for Bacterial Attachment and Microbiologically Influenced Corrosion— Kurissery R. Sreekumari1; *1 , Yoshihiro Sato2 and Yasushi Kikuchi1; *2 1 Joining & Welding Research Institute, Osaka University, Ibaraki, Osaka 567-0047, Japan Department of mechanical & Physical Engineering, Graduate School of Engineering, Osaka City University, Osaka 558-8585, Japan 2 Microbiologically Influenced Corrosion (MIC), otherwise coined as biocorrosion, is the influence of microorganisms on the kinetics of corrosion processes of metals, minerals and synthetic materials caused by their adhesion and growth. A closer observation of the MIC failure case analyses of engineering components showed that MIC occurs at or near welds. Preferential bacterial attack on the austenite phase leaving a skeleton like appearance is commonly reported on welds. The initial step of this phenomenon is the attachment of bacteria, which, over a period of time develop into a biofilm on the material surface. However, the intriguing question that remains to be answered is ‘‘Why welds are prone to preferential MIC attack?’’ Experiments on bacterial attachment on stainless steel surfaces revealed that surface roughness plays a pivotal role. Naturally, welds are with rough surfaces and that explains the preferential attachment of bacteria. Also, it was noticed that shape of the weld beads, determines the extent of bacterial attachment on to their surfaces. Leaving apart the surface roughness as the major contributing factor for the preferential bacterial attachment, studies were carried out to determine whether the underlying microstructure has any influence on it. Results suggested that there is. There was significant difference in percentage area of bacterial attachment between base metal and weld even after nullifying the surface roughness by polishing. Weld metal was preferred for attachment by bacteria more than base metal. Subsequent studies using an image superimposing technique revealed that grain boundary or the austenite/ferrite interface was preferred by bacteria as their initial attachment site. Welds have more such interfaces/or grain boundaries than base metal and thus resulting in more bacterial attachment, quickly leading to the initiation of MIC. The influence of inclusions, energy gradient and alloying elements are also discussed as factors associated with this phenomenon. In order to test the effect of elemental segregation occurring at grain boundaries on bacterial attachment, experiments were carried out using sulfur enriched stainless steel welds as well as high nitrogen stainless steels. Presence of sulfur and nitrogen as alloying elements enhanced bacterial attachment. Sulfur and nitrogen are essential elements for bacterial growth and their presence must have enhanced bacterial attachment. This result led us to the development of antibacterial metals. The hypothesis that worked out was if essential elements enhance attachment, toxic elements should deter it. Controlling bacterial attachment would be beneficial, both for deterring MIC and preventing infection and maintaining hygiene, especially in hospitals and food industries. Silver and copper, the well-known toxic elements were tried as alloying elements in stainless steel. While doing so, the material properties were kept largely in par with the silver/copper free stainless steel. The efficiencies of these antibacterial stainless steels were tested in the laboratory and were found to resist bacterial attachment and MIC. Silver containing stainless steels were tested in a freshwater environment as well. They were found to resist microfouling build up until a period of one month (the maximum duration of the study). Coupon exposure studies for longer duration are being carried out in our laboratory. In order to help in the development of high quality antibacterial metals, a base line data on the antibacterial efficacies of different candidate alloying elements are necessary. For this purpose, various metals were tested for their antibacterial efficacy using a standard method, known as film contact method as well as conventional coupon exposure tests. This chapter also discusses the merits and de-merits of antibacterial metals and their applications. (Received January 24, 2005; Accepted April 6, 2005; Published July 15, 2005) Keywords: antibacterial metals, microbiologically influenced corrosion, bacteria, corrosion, weld, stainless steels, silver, copper 1. Introduction Biofilm formation on surfaces of importance whether it is for industries or biomaterials is a matter of significant concern.1) Biofilms could be deleterious to materials, when they induce corrosion.2) As the microorganisms grow on substratum surfaces, they produce various metabolic byproducts, which might promote deterioration of the underlying substratum. These reactions refer to biocorrosion or microbiologically influenced corrosion (MIC) when the underlying substratum is a metal or metal alloy.3) Microbiologically influenced corrosion (MIC) is a serious problem in a number of industries including power generation, petrochemical, pulp and paper, gas transmission and shipbuilding. Conservative estimates place the direct cost of MIC at US$ 30 to 50 billion/year.4) The magnitude of the problem necessitates a wider attention that might encompass collaboration between established research groups or laboratories *1Present address: Department of Biology, Lakehead University, 955 Oliver Road, Thunder Bay, Ontario, Canada P7B 5E1 *2Professor Emeritus, Osaka University specializing researches on various aspects of metal microbe interactions viz. microbiology, metallurgy, civil & environmental engineering and biotechnology. The role of bacteria and their associated biofilm play in MIC drove the attention of scientists from the late 1970s.5) Since long, MIC has been referred to as the cause for deterioration of various materials and the combination of unexpected attack and rapid failure make MIC a matter of considerable concern in many applications.4) Whatever be the material and mechanisms involved, one of the striking observations is the consistent incidence of MIC at and near welds. The formation and succession of biofilms depend on the environmental and biological factors as well as the surface characteristics of the materials. MIC is reported in various materials and it is well known that microbes settle preferentially on different materials. High purity metals frequently have low mechanical strength thus making it necessary to alloy elements thus can improve mechanical, physical, fabrication and corrosion characteristics. Alloys are inhomogeneous, with discontinuous compositions and anisotropic properties from an atomic scale to a macroscopic scale. The microscopic heterogeneity of engineered materials, whether Antibacterial Metals —A Viable Solution for Bacterial Attachment & MIC— created intentionally or as an artifact, is the basis for their properties. The heterogeneity is evident on the scale of microbes and is an important factor in MIC. Weld regions are particularly attractive to microbes as the welding alters the material surface characteristics.6) There are reports on the influence of alloy composition,7) manufacturing specifications such as surface finish and heat treatments and presence of protective coatings on MIC susceptibility.8) The topological, chemical and microstructural alterations resulted by welding may increase the corrosion susceptibility of the welded region.9) A majority of cooling system failures of corrosion resistant alloys is reported to be occurring around or within weldments.8,10–13) The combination of physical and compositional changes brought about by the welding process is believed to facilitate accumulation of organics onto the surface and subsequent colonization by bacteria.14,15) Since the report of Olsen and Szybalski,16) the preference of weld as a site of colonization by bacteria is evident and was correlated to the surface roughness. Kikuchi and Matsuda17) in a review pointed out that HAZ might show a changed internal structure and composition and may in some circumstances act as a location where corrosion can be preferentially initiated. Walsh4) and the studies at Joining and welding Research Institute (JWRI), Osaka University,18–20) showed influence of surface chemistry and microstructure on bacterial attachment on welds. Typical MIC failure cases analyzed in JWRI, Osaka University leaving stainless steel welds with a skeleton appearance is shown in Fig. 1. 2. Studies on MIC of Stainless Steel and Its Welds Studies on bacterial adhesion on welds compared to base metals of stainless steel showed that, there is a significant Fig. 1 MIC on SS 304 L welds (A) Stainless steel weld showing the skeleton type corrosion due to microbial influence (B) Stainless steel experimental coupons showing bacteria attached adjacent to corrosion pits. 1637 Fig. 2 Epifluorescence microscopic images showing the variation in bacterial attachment on different coupons of SS 304 L (base metal and weld (as weld or without polishing)) and graph showing the variation in percentage area of attachment of bacteria on different coupons as a function of exposure time. The bacterium used was Pesudomonas sp. difference in the bacterial attachment, with welds showing very high bacterial attachment compared to HAZ (heat affected zone) or base metal (Fig. 2). The settlement assay was carried out with two different bacteria both isolated from ground water corrosive environment in Japan, viz. Pseudomonas sp. and Bacillus sp., a gram negative and positive strain, respectively. The reasons for the preferential colonization of bacteria near the welds were thought as the substratum roughness and difference in material composition and therefore the surface properties.21) It is known for quite some time that the attachment of organisms vary with the surface roughness, with rough surfaces harboring more attachment while the smooth less. This could again be related to the surface free energy. As pointed by Lindner,22) the more the surface energy, the more the chances of attachment are. Also, as the surface energy increases, the strength of attachment increases. This is because the adhesive strength is the sum of the surface free energy of the solid surface and the surface tension of the water column minus the interfacial surface tension between the solid and liquid. Therefore, the more the free surface energy, the more the strength of attachment is. Increased attachment of microbes in the welded area especially with respect to the shape and size of the weld bead have been studied by Amaya et al.23) They have found that, on the weld bead, the toe possessed the maximum attachment as compared to the top most portion of the bead (Fig. 3). They have explained the results taking into the water movements changes happening over the bead (coupons were incubated inside a bioreactor (flasks) which were shaken constantly over an incubator shaker). 1638 K. R. Sreekumari, Y. Sato and Y. Kikuchi Fig. 3 Variation in percentage area of bacterial attachment on different regions of weld (304 L SS). Experiments were conducted in the laboratory. In a related study at JWRI, Osaka University, Sreekumari et al.24) have observed that there are factors other than the surface roughness playing a role to determine the bacterial attachment on to material surfaces. This is because an increased bacterial attachment on the welded area compared to HAZ or base metal of stainless steel was observed (Fig. 4) even after the surfaces were polished to 1 mm finish.24) Two factors were thought to have influenced the attachment of bacteria on a polished surface. They are, (1) the role of microstructure on the bacterial attachment, and (2) the inclusions or the re-distribution of elements in the weld region occurring as a result of welding. Experiments that addressed to study the role of substratum microstructure on bacterial attachment showed that the initial attachment of bacteria occurred largely on or near the grain boundaries or austenite/ferrite interface (in the case of welds) (Fig. 5). It is true that, the surface energy is different between the matrix and the grain boundary on a substratum surface with grain boundary having more surface energy than the matrix.25) In addition, the concentration of certain elements such as sulfur, phosphorus etc. are more at the grain boundary compared to matrix, which in turn might have influenced the bacterial attachment.24) Therefore, from these results it was suggested that, since the bacteria attached more on the grain boundaries and since such boundaries are more in the welded area (length of grain boundary or austenite-ferrite interface/unit area) compared to matrix, more attachment occurred on weld than on base metal. The increased attachment of bacteria at the welds over a period of time might result in MIC (Fig. 6). In order to get more information on the preferential bacterial attachment on the grain boundaries, as explained above, we have studied the influence of elemental enrichment during welding. In order to address this aspect, two sets of detailed bacterial attachment studies were conducted, one on the sulfur enriched stainless steel and other on high nitrogen steels (HNS). 3. Bacterial Attachment on Sulfur Enriched Steel Stainless steel welds were prepared by incorporating sulfur during welding at JWRI, Osaka University. Studies on the bacterial adhesion on sulfur enriched stainless steel welds showed that it is a preferred site for bacterial adhesion26) compared to normal stainless steel weld and thus is more susceptible to MIC.6) Sulfur is an essential element for bacterial metabolism and therefore it could be acting as a chemical cue to attract bacteria. The experiments were conducted using Pseudomonas sp., an isolate from a ground water corrosive environment in Japan (Fig. 7). 4. Fig. 4 Epifluorescence microscopic images showing the variation in bacterial attachment on different coupons (SS 304 L polished to 1200 mm finish) and graph showing the variation in percentage area of attachment of bacteria on different coupons as a function of exposure time. The bacterium used for the study was Pseudomonas sp. Bacterial Attachment Studies on HNS Steels containing more than 0.08 weight percent nitrogen in ferritic matrix or 0.4 weight percent nitrogen in an austenitic matrix are considered as high nitrogen stainless steels (HNS),27) though nitrogen is a universal alloying element in steels. High nitrogen concentration has both beneficial (creep resistance, solid solution hardening, grain growth etc.) and detrimental (various embrittlement phenomena) impacts.28) However, recently HNS are preferred for many commercial purposes, as they possess improved structural stability and corrosion resistance than the other classes of steels.27) For the ‘‘nickel allergy’’, a kind of hypersensitivity of human bodies with symptoms of inflammation, eczema and irritation on contact with nickel containing steels,29) nickel free stainless steel, where, nickel is replaced with nitrogen is a possible remedy. Antibacterial Metals —A Viable Solution for Bacterial Attachment & MIC— 1639 Fig. 5 Superimposed images (epifluorescence and bright field) of base metal, and weld metal coupons of SS 304 L showing grain boundary preference of Pseudomonas sp. Fig. 7 Percentage area of attachment of Pseudomonas sp. on different types of SS 304 L coupons. Fig. 6 SEM photomicrograph of 304-L stainless steel weldmetal coupon exposed to Pseudomonas sp. for 16 days showing a skeleton type of corrosion. The results of the laboratory studies conducted at JWRI, Osaka University, where the attachment of Pseudomonas sp. on three different materials such as AISI type 304L, 304 LN, 0.4% HNS was studied, invariably showed bacteria adhesion is more on the high nitrogen stainless steel compared to the other two types of materials tested (Fig. 8). The HNS surfaces immersed in aqueous medium provides a rich substratum for these types of microbes, as there is production of ammonia and nitrites, which are essential compounds for the bacteria. The attachment of these bacteria and their growth and metabolic activities might result in microbiologically influenced corrosion of HNS. It is also known that elemental composition on the surfaces act as chemical cues by which bacterial adhesion is facilitated or mitigated.30) The attached bacteria would utilize the ammonia/nitrite formed over the substratum surface for their metabolic activities might leave the surface prone to localized corrosion. Among the 304L and HNS coupons exposed to bacteria, HNS coupons showed 1640 K. R. Sreekumari, Y. Sato and Y. Kikuchi ,t/d Fig. 8 Bacteria seen adhered to HNS and 304 L coupons after 16 days of exposure to Pseudomonas sp. and percentage area of bacterial adhesion on different coupons as a function of exposure time. , t/d Fig. 9 Variation in free corrosion potential as a function of exposure time. more positive free corrosion potential (Fig. 9). Especially, in the case of exposure to Nitrosomonas sp., the ennoblement was significant as compared to the control material. This shows the HNS is about to start corroding faster than the other two materials. 5. Antibacterial Material Bacteria are getting attracted towards certain elements, as they might be useful for their life via components of metabolic activity modulators. As explained before, essential elements such as nitrogen and sulfur attracted bacterial settlement, meaning that there could be elements that could reduce attachment as well, as the elements may be toxic to them. This logic lead to the concept that, if elements those are toxic are incorporated in a belittle quantity, just sufficient to be sensed by these microorganisms, could give an antibacterial property to otherwise a preferred settlement material.21) This resulted in the manufacturing of antibacterial stainless steels. Stainless steel is the most widely used material in industries. The forgoing section summarizes that bacteria attach quickly onto stainless steels initiating corrosion. Non-metallic antibacterial materials are available in the market. However, antibacterial metals are scarce. This makes studies on antibacterial metals challenging and promising. Nakamura et al.31) and Yokota et al.32) have reported on the antibacterial properties of Cu and Ag bearing stainless steels, respectively. Antibacterial property of silver is known since centuries. As silver is non-toxic to human beings, it has been used for healing wounds as well as water purifier in swimming pools and space shuttles. This makes silver as an ideal antibacterial element. Metallic elements in stainless steels may be difficult to ionize due to the existence of a passive film on the stainless steel. It is presumed that only a reduced passive film formation only occur on metallic particles of Cu and Ag that are found on the surface of Cu and Ag containing stainless steel.32) This would allow the ionization of Cu and Ag, and as a result, stainless steels with these elements exhibit antibacterial property. Yokota et al.32) reported that, Ag bearing stainless steels exhibited significant antibacterial property, and the corrosion resistance was as good as normal stainless steel. Also the antibacterial efficacy of Ag ions is several hundred times stronger than that of Cu or Ni.32) It has also been demonstrated that Ag ions infiltrate into cell membranes more rapidly than Cu or Ni ions.33) This makes the amount of Ag required to obtain antibacterial effect to very minimum in comparison with other elements tested so far. Antibacterial stainless steels would benefit many industries particularly food and hospital where it could reduce infections. Therefore, AISI type 304 stainless steels containing silver were prepared (<0:039 mass%) with the help of steel making industries and evaluated for their antibacterial property through laboratory and field experiments. 6. Laboratory and Field Experiments on Cu Containing Stainless Steels Coupon exposure studies using Cu containing stainless steel showed a significant reduction in the bacterial adhesion as compared to plain stainless steels (control) (Fig. 10). The bacterial exposure studies were performed using Bacillus sp., an isolate from a MIC failure case analyzed in JWRI, Osaka University, Japan. The Cu contained stainless steel was manufactured by a steel maker in Japan that had a collaborative research program with JWRI, Osaka University. 7. Laboratory and Field Experiments on Ag Containing Stainless Steels Laboratory coupon exposure study using Pseudomonas sp. culture of 304 SS, silver alloyed (514) and silver coated (BC) 304 SS showed, a significantly reduced bacterial settlement on silver containing stainless steels as compared to plain stainless steel coupons. Among the two types of silver incorporated stainless steels, 514 showed higher resistance to bacterial attachment than the silver coated ones (Fig. 11) The differences among the three types of steels were found to be statistically significant (t-test, p < 0:05). With respect to the corrosion initiation by these bacteria on these materials, 304 coupons showed highly pitted surfaces by 30 days. Pits were generally observed in association with the biofilm (Fig. 12). Very less number of corrosion pits could be observed on BC coupons. However, on the 514 coupons, the bacterial attachment was very low and pits were almost absent (Fig. 12). Fields without bacterial cells were common on Antibacterial Metals —A Viable Solution for Bacterial Attachment & MIC— 1641 Fig. 10 Epiflourescence microscope images showing Bacillus sp. attached to surfaces of different coupons after 2 days exposure (A. 304 SS base metal B. Cu contained SS base metal C. 304 SS weld (polished) D. Cu contained weld (polished) E. 304 SS weld (as welded) F. Cu contained weld (as welded). Fig. 12 Scanning Electron Microscopic images of different base metal coupons after 30 days of exposure to Pseudomonas sp. Fig. 11 Epiflourescence microscopic images of Pseudomonas sp. adhered on to different base metal coupons after 6 days of exposure and graph showing the variation in % area of adhesion of Pseudomonas sp. on different materials. 514 coupons. On BC coupons patches supposed to be the left over by the detached bacteria could be seen. On control coupons, where coupons only were exposed to media, no pit formation was observed (Sreekumari et al., 2002). In order to find out the action of silver ions on these bacteria, transmission electron microscope study on the cells of Pseudomonas sp. scrapped off from the surface of silver alloyed stainless steel coupons was performed (Fig. 13). The images revealed that silver is getting deposited inside the bacterial cells. The black spots inside the cells, which could not be observed in live cells, indicated the accumulation of silver (Fig. 14). There are different opinions about the mechanisms of how silver affects cell death.34) One of them is that metallic ions like Agþ or Cuþ infiltrating into the cell membranes of the bacteria where they combine with the SH group of the dehydrase which controls the respiration. Usually when a metal with no biological function competes 1642 K. R. Sreekumari, Y. Sato and Y. Kikuchi Fig. 13 Transmission electron micrograph of Pseudomonas sp. adhered on silver containing stainless steel surfaces. with or replaces a functional metal, toxicity results.35) The study thus showed that the bacteria in contact with the surface are the most affected ones. It would be possible then for the cells to get attached to the already attached cells and thus escape from the direct contact with silver. But from the results it is clear that once the cells in contact are dead, there is a tendency to slough off leaving patches on the substratum surface. TEM observation showed a significant damage to the bacterial cells especially on their cell wall. Though the concentration of silver inside the cells could not be quantified analytically, sites resembling metal deposition were observed both over the cell surface and inside the cell. Since the results of the laboratory experiments were encouraging, Sreekumari et al. have also studied the efficacy of silver containing stainless steels in a natural environment. For this purpose, experiments were conducted in a fresh water pond for about 30 days. The results also showed encouraging results. The variation in total cultivable viable count of biofilm bacteria in the biofilm of different coupons over the period of time of coupon exposure showed remarkable difference (Fig. 15). While the 304SS coupons showed the highest number of attached bacteria, 514 and BC showed significantly lower number of bacteria. Among the two, BC produced the maximum impact (Fig. 15). 8. Corrosion Potential Fluctuation in Ag Containing Stainless Steels Corrosion probability of silver containing stainless steels also had been monitored in the laboratory. The free corrosion potential during the 60-day study showed significant difference among the three types of materials. After the initial drop in potential it increased and continued to be above the initial Fig. 14 Transmission electron micrograph showing cell damage in Pseudomonas sp. adhered on silver containing stainless steel surfaces (A magnified view). value in the case of 304 and BC coupons. However, the potential did not show much fluctuation on the 514 coupons throughout the study period. What was interesting is that, free corrosion potential variation followed a similar trend as that of bacterial adhesion. Free corrosion potential did not show any change on medium control coupons (Fig. 16). 9. Baseline Data on Antibacterial Efficacy of Different Metals and Alloys A standardized test for antibacterial efficacy, the film contact method was used to investigate the ability of different metals to resist bacterial attachment. Zn, Ni, Pb, Co, Mo, Zr, Cu, Sn, and Ti were used for this purpose. Except Sn and Ti, all other metals showed profound antibacterial property by reducing the colony forming units (cfu) of bacteria on their surface to less than 101 from 106 within a period of 24 hours (Fig. 17). The test was conducted using both Escherichia coli and Staphylococcus aureus. Two copper alloys tested (Cu– Zn and Cu–Sn) also showed antibacterial properties by Antibacterial Metals —A Viable Solution for Bacterial Attachment & MIC— 1643 Fig. 15 The variation in total viable count of biofilm bacteria on different coupons exposed in a freshwater pond over a period of time. Fig. 18 Results of the antibacterial efficacy test on different alloys. The test strain was Staphylococcus aureus. Fig. 16 Variation in free corrosion potential of different base metal coupons as a function of exposure time. Coupons were exposed to Pesudomonas sp. in the laboratory. Fig. 19 The reduction in the cfu of Staphylococcus aureus in contact with different metals. The observations were conducted intermittently over a very short duration of 24 h. Fig. 17 Results of the antibacterial efficacy test on different pure metals. The test strain was Staphylococcus aureus. reducing the cfu to less than 101 from 106 within an hour of contact (Fig. 18). It was assumed that the rate of reduction occurring on different metals will be different over a period of shorter time intervals before reaching the final zero cfu level within 24 h and therefore further experiments were carried out with shorter sampling intervals of bacterial cells in contact with the surfaces. The results are shown in Fig. 19. From the slope of the curves, the relative antibacterial efficacy was determined. The results showed that Pb followed by Co and Cu were most effective metals those resisted bacterial attachment and growth by causing mortality. Thus these elements could be carefully considered as antibacterial elements that could be incorporated in different alloying 1644 K. R. Sreekumari, Y. Sato and Y. Kikuchi Fig. 20 Transmission electron micrographs showing Staphylococcus aureus cells observed after contact with different metals. situations to resist bacterial attachment. This could pave way for the development of novel antibacterial metals in future. 10. TEM Observation for Cell Damage Transmission electron microscopy was used to evaluate the bacterial cell damage occurred in the case of different antibacterial metals tested (Fig. 20). Though detailed investigation to the mechanisms involved is yet to be completed, it was evident from the Figures that the cell damage pattern was different for different metals. 11. Conclusions Bacterial attachment and the consequent biofilm formation might be the preliminary step leading to microbiologically influenced corrosion. It is known that surface roughness plays a major role in enhanced bacterial attachment on welds. Studies were carried out to investigate any other possible factors influencing it other than surface roughness. The results were promising and pointed out the role of microstructure on bacterial attachment. The grain boundaries or austenite ferrite interfaces were preferred by Pseudomonas sp. and the reasons were thought to be as the energy difference or elemental segregation at these locations. Sulfur enriched welds and high nitrogen stainless steel showed more bacterial attachment compared to AISI type 304 stainless steel. 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