High-Performance Ceramic Coatings: Markets and Technologies

REPORT HIGHLIGHTS

• The North American market for high-performance ceramic coatings was worth $1.3 billion in 2010 and $1.4 billion in 2011. It is expected to grow to more than $2.0 billion by 2016, a projected five-year compound annual growth rate (CAGR) of 7.4%.
• The thermal spray technology market was worth $896.5 million in 2010 and $935.2 million in 2011. It is expected to grow to $1.3 billion by 2016, a projected five-year CAGR of 7.8%.
• The PVD technology market was worth $199 million in 2010 and $208.4 million in 2011. It is expected to grow to $294.6 million by 2016, a projected five-year CAGR of 7.2%.

INTRODUCTION

For more than 20 years, BCC Research has been tracking developments in the high–performance ceramic coatings market.  Since the last edition of this report was published in 2010, significant changes have taken place in the ceramic coating service industry.  In view of these changes, BCC decided that there is now a need to update the previous edition’s findings and conclusions.

STUDY GOALS AND OBJECTIVES

This report is intended to

• Provide an industry overview of ceramic coatings delivered by thermal spray, physical vapor deposition (PVD), chemical vapor deposition (CVD) and other techniques, including spraying/dipping, sol gel, micro-oxidation, packed diffusion, ionic beam surface treatment and laser-assisted techniques.
• Determine the current size and future growth of the North American markets for ceramic thermal spray, PVD, CVD and other coatings services.
• Provide a technology overview, including material types, properties and applications for ceramic coatings.
• Analyze domestic competition among companies within each of the ceramic coating service segments.
• Profile all North American equipment manufacturers, service providers and suppliers of consumables among ceramic thermal spray, PVD, CVD and other coating techniques.
• Identify the users of ceramic coating services.

REASONS FOR DOING THE STUDY

Ceramic coatings constitute a large family of materials with quite diverse compositions and properties.  They include compositions based on alumina, alumina–magnesia, chromia, hafnia, silica, silicon carbide, titania and zirconia.  Ceramic coatings are generally applied to metal or metallic alloy components or to ceramic components

High–performance ceramic coatings are a special class of ceramics in their form and the preparation techniques required.  However, their uses are diverse, and they exploit the wide range of unique and desirable properties of various bulk ceramics.  Ceramic coatings are generally used for wear- (or erosion-), corrosion- and high temperature-resistant applications.  All ceramic coatings deliver some level of performance in each of the three major areas listed above.

The availability and commercialization of high–performance coatings have already changed the internal specification patterns of certain industries, such as cutting tool inserts.  The useful life of coated inserts is many times the life of uncoated inserts.  This, in turn, has reduced the cost of cutting tool inserts and at the same time has increased productivity.  Similarly, ceramic–coated components for aircraft turbine engines resulted in building large aircraft.  Now, auto enthusiasts are coating certain auto engine components to improve auto engine performance.  Also, ceramic coatings have made it possible for certain large machine components to be repaired in situ.

INTENDED AUDIENCE

This new BCC study provides an in–depth analysis of the materials, applications, economics, current markets and trends, and the players.  Forecasts are provided for each major market segment through 2016.  In–depth analyses have been provided for the North American ceramic coatings industry structure, providing detailed information on major players and markets for each application.

Through this report, BCC hopes to provide a better understanding of the North American ceramic coatings industry.  This study provides the most up-to-date information we have gathered on the high–performance ceramic coatings market segments.  The report further describes various kinds of ceramic deposition technologies, new developments and recent patents, advantages and limitations of currently used techniques, and profiles of all North American players involved in this industry.

This study is directed to the various strata of companies and institutions interested in the markets and new developments in this growing field.  They are:

• Companies involved in developing, manufacturing and supplying advanced materials.
• Companies involved in the development and manufacture of high-performance metallic and ceramic components.
• Suppliers of advanced ceramic powders and components.
• Manufacturers and suppliers of thermal spray, PVD, CVD and ionic beam and laser beam coating equipment.
• Producers of vacuum equipment.
• Suppliers of coating consumables.
• Providers of coating services.
• OEM suppliers.
• Government agencies involved in advanced materials research.
• Producers of aircraft engines and/or engine components.
• Companies doing repair and refurbishing of aircraft engines.
• Producers of automotive and diesel engines.
• Job shops providing coating services to racing car and other auto engines.
• Producers of cutting tools, bearings, textile guides and pulleys, extrusion and drawing dies, nozzles, mechanical seals and valves, and other wear-resistant parts.
• Companies involved in the development and use of ceramics and high-performance ceramic coatings for aerospace and military applications.
• Venture capital companies and financial institutions interested in new and attractive investments.

SCOPE AND FORMAT

This BCC study has been conducted with a global perspective in terms of materials and their applications.  Market projections have been conducted for North America.  All market table values are in 2010 U.S. dollars.

The report provides business planners and managers with an improved understanding of the direction and impact of the high-performance ceramic coating technologies, and how markets will be affected and new opportunities created.

The report contains

• An in-depth analysis of the technologies used for high--performance ceramic coatings.
• An overview of materials for high-performance ceramic coatings and their properties.
• New developments and recent patents in high-performance ceramic thermal spray, PVD, CVD and other coating techniques.
• Current and potential applications for high-performance ceramic coatings.
• Current and future market projections for ceramic coatings in all the major applications.
• Profiles of current industry players, including suppliers of equipment, consumables, coating service providers and users.
• A review of the economic/market opportunities for current industry participants and new entrants.

BCC feels, therefore, that the qualitative and quantitative judgments embodied in this report are a valuable contribution to the current knowledge of high-performance ceramic coatings.

METHODOLOGY AND INFORMATION SOURCES

This report is an updated version of a report originally published in 2004 and subsequently updated in 2007 and 2010.  Both primary and secondary research methodologies were using in preparing this report.  Information for the original and updated reports were collected through extensive industry contacts with people active in the research, development, production and use of high-performance ceramic coatings, from government and academic sources, and by reference to technical literature.  Several industry experts were also interviewed for this study.  In addition, most of the coating service providers and end users were contacted to evaluate current and future demands for these coatings.

More than 200 industry contacts assisted BCC in identifying and updating technologies and applications.  In addition to utilizing its in-house database on ceramic coatings, BCC conducted extensive Web searches to gather and analyze all pertinent information related to this study.  Major technical and trade publications and conference proceedings in ceramic coatings were also used for this study.

Table of Contents

Chapter- 1: INTRODUCTION
STUDY GOALS AND OBJECTIVES
REASONS FOR DOING THE STUDY
INTENDED AUDIENCE
SCOPE AND FORMAT
METHODOLOGY AND INFORMATION SOURCES
AUTHOR’S CREDENTIALS
RELATED BCC REPORTS
BCC ONLINE SERVICES
DISCLAIMER

Chapter- 2: EXECUTIVE SUMMARY
Table Summary : NORTH AMERICAN MARKET FOR HIGH-PERFORMANCE CERAMIC COATINGS BY TYPE OF COATING TECHNOLOGY, THROUGH 2016
Figure Summary : MARKET SHARE OF NORTH AMERICAN HIGH-PERFORMANCE CERAMIC COATING TECHNOLOGIES, 2010-2016

Chapter- 3: INDUSTRY OVERVIEW
INDUSTRY STRUCTURE
TECHNICAL AND BUSINESS ISSUES
NORTH AMERICAN MARKETS
Table 1 : NORTH AMERICAN MARKET FOR HIGH-PERFORMANCE CERAMIC COATINGS, BY APPLICATION SEGMENT, THROUGH 2016
Figure 1 : SHARE OF NORTH AMERICAN HIGH-PERFORMANCE CERAMIC COATING SERVICE MARKET SEGMENTS, 2010–2016

Chapter- 4: TECHNOLOGY OVERVIEW
MATERIAL TYPES AND PROPERTIES
COATING TECHNIQUES
GENERAL APPLICATIONS
Table 5 : LEADING APPLICATIONS OF DEPOSITION BY INDUSTRY
Table 6 : TYPICAL COATINGS AND APPLICATIONS

Chapter- 5: THERMAL SPRAY
THERMAL SPRAY TECHNIQUES
APPLICATIONS
RECENT DEVELOPMENTS
INDUSTRY STRUCTURE
NORTH AMERICAN MARKETS

Chapter- 6: PHYSICAL VAPOR DEPOSITION (PVD)
BASIC PRINCIPLES
PVD MATERIALS
PVD TECHNOLOGIES
PVD ADVANTAGES AND LIMITATIONS
PVD APPLICATIONS
RECENT DEVELOPMENTS
INDUSTRY STRUCTURE
NORTH AMERICAN MARKETS
Table 41 : NORTH AMERICAN HIGH-PERFORMANCE CERAMIC PVD COATING MARKET, THROUGH 2016
Figure 6 : SHARE OF NORTH AMERICAN CERAMIC THERMAL SPRAY COATING SERVICE MARKET SUBSEGMENTS, 2010–2016

Chapter- 7: CHEMICAL VAPOR DEPOSITION (CVD)
BASIC PRINCIPLE
CVD MATERIALS
CVD TECHNIQUES
CVD APPLICATIONS
NEW DEVELOPMENTS
INDUSTRY STRUCTURE
NORTH AMERICAN MARKET
Table 56 : NORTH AMERICAN CERAMIC CVD COATING SERVICE MARKETS BY APPLICATION, THROUGH 2016
Figure 8 : SHARE OF NORTH AMERICAN CERAMIC CVD COATING SERVICE MARKET SEGMENTS, 2010-2016

Chapter- 8: OTHER COATING TECHNIQUES
SPRAYING, BRUSH PAINTING AND DIPPING
ELECTRODEPOSITION
CEMENTATION
SOL GEL PROCESSING
USING LASERS FOR COATING
ION-BEAM-ASSISTED DEPOSITION (IBAD)
ION BEAM SURFACE TREATMENT (IBEST)
ION-BEAM-ENHANCED DEPOSITION (IBED)
MICRODISCHARGE DEPOSITION
MICROPLASMIC COATING
INDUSTRY STRUCTURE
NORTH AMERICAN MARKET

Chapter- 9: COMPANY PROFILES
PROFILES OF NORTH AMERICAN COMPANIES INVOLVED IN CERAMIC COATINGS AS EQUIPMENT MANUFACTURERS, SUPPLIERS OF CONSUMABLES, COATING SERVICE PROVIDERS AND USERS

List of Tables

Summary Table : NORTH AMERICAN MARKET FOR HIGH-PERFORMANCE CERAMIC COATINGS BY TYPE OF COATING TECHNOLOGY, THROUGH 2016
Table 1 : NORTH AMERICAN MARKET FOR HIGH-PERFORMANCE CERAMIC COATINGS, BY APPLICATION SEGMENT, THROUGH 2016
Table 2 : HIGH-PERFORMANCE CERAMIC COATING MATERIALS AND GENERAL APPLICATIONS
Table 3 : REPRESENTATIVE FLAME AND PLASMA-SPRAYED MATERIALS, MELTING OR SOFTENING TEMPERATURE, USES
Table 4 : PLASMA-SPRAYED CERAMIC COATING PROPERTIES
Table 5 : LEADING APPLICATIONS OF DEPOSITION BY INDUSTRY
Table 6 : TYPICAL COATINGS AND APPLICATIONS
Table 7 : CERAMIC MATERIALS USED IN THE POWDER FLAME PROCESS
Table 8 : PROPERTIES OF HVOF CARBIDE COATINGS
Table 9 : COMPARISON OF THERMAL SPRAY PROCESSES
Table 10 : DETONATION GUN APPLICATIONS IN THE GAS TURBINE ENGINE
Table 11 : THERMAL SPRAY COATINGS FOR FRPS
Table 12 : RECENT DEVELOPMENTS IN THERMAL SPRAY COATINGS
Table 13 : LEADING U.S. COMPANIES PROVIDING THERMAL SPRAY COATING SERVICES FOR OEM PARTS
Table 14 : NORTH AMERICAN CUSTOM/JOB SHOPS PROVIDING THERMAL SPRAY COATING SERVICES
Table 15 : LEADING U.S. COMPANIES PROVIDING THERMAL SPRAY COATING CONSUMABLES
Table 16 : U.S. COMPANIES SUPPLYING CONSUMABLES FOR NANOCERAMIC COATINGS
Table 17 : U.S. MANUFACTURERS OF PLASMA SPRAY EQUIPMENT
Table 18 : ACQUISITIONS, MERGERS AND OTHER BUSINESS RELATIONS IN THE THERMAL SPRAY INDUSTRY SINCE 1990
Table 19 : TOTAL NORTH AMERICAN EXPENDITURES ON THERMAL SPRAY CERAMIC COATING OF AIRCRAFT GAS TURBINE PARTS, THROUGH 2016
Table 20 : NORTH AMERICAN SHIPMENTS OF TURBOFAN, TURBOPROP AND TURBOSHAFT ENGINES, THROUGH 2016
Table 21 : COST OF AIRCRAFT ENGINE COATING SERVICES, THROUGH 2016
Table 22 : NORTH AMERICAN AIRCRAFT GAS TURBINE ENGINE OVERHAUL MARKET THROUGH 2016
Table 23 : TOTAL NORTH AMERICAN EXPENDITURES ON THERMAL SPRAY CERAMIC COATING OF LARGE LAND-BASED TURBINE PARTS, THROUGH 2016
Table 24 : COST OF NEW LARGE LAND-BASED TURBINE COATING SERVICES, THROUGH 2016
Table 25 : COST OF LARGE LAND-BASED TURBINE REFURBISHMENT COATING SERVICES, THROUGH 2016
Table 26 : TOTAL NORTH AMERICAN EXPENDITURES ON THERMAL SPRAY CERAMIC COATING OF WEAR-RESISTANT PARTS AND INDUSTRIAL APPLICATIONS, THROUGH 2016
Table 27 : TOTAL NORTH AMERICAN EXPENDITURES ON THERMAL SPRAY CERAMIC COATINGS IN AUTOMOTIVE AND DIESEL ENGINES, THROUGH 2016
Table 28 : TOTAL NORTH AMERICAN EXPENDITURES ON THERMAL SPRAY CERAMIC COATINGS FOR MEDICAL APPLICATIONS, THROUGH 2016
Table 29 : NORTH AMERICAN CERAMIC THERMAL SPRAY COATING MARKET, THROUGH 2016
Table 30 : MARKET SHARE OF THERMAL SPRAY COATING SERVICE PROVIDERS, 2010
Table 31 : REPRESENTATIVE FILMS DEPOSITED BY PVD
Table 32 : REPRESENTATIVE PVD SURFACE COATINGS FOR ABRASION- AND CORROSION-RESISTANT APPLICATIONS
Table 33 : TYPES OF PHYSICAL VAPOR DEPOSITION PROCESSES
Table 34 : BASIC SPUTTERING SOURCES AND PROCESSES
Table 35 : COMPARISON OF MAGNETRON SPUTTERING METHODS FOR DEPOSITING SIO2
Table 36 : CERAMIC PVD APPLICATIONS
Table 37 : PROPERTIES OF UNCOATED AND TIN-COATED HIGH SPEED STEEL (HSS)
Table 38 : PROPERTIES AND APPLICATION OF VARIOUS BALZERS BALINIT THIN-FILM WEAR-RESISTANT COATINGS
Table 39 : RECENT DEVELOPMENTS IN PVD
Table 40 : LEADING NORTH AMERICAN COMPANIES MANUFACTURING PVD SYSTEMS AND/OR PROVIDING SERVICES
Table 41 : NORTH AMERICAN HIGH-PERFORMANCE CERAMIC PVD COATING MARKET, THROUGH 2016
Table 42 : NORTH AMERICAN MARKET FOR CERAMIC PVD TOOL COATINGS, THROUGH 2016
Table 43 : NORTH AMERICAN MARKET FOR CERAMIC COATINGS FOR AUTOMOTIVE, AEROSPACE AND WEAR-RESISTANT APPLICATIONS, THROUGH 2016
Table 44 : NORTH AMERICAN MARKET FOR CERAMIC PVD MEDICAL DEVICE COATINGS, THROUGH 2016
Table 45 : MARKET SHARE OF CERAMCI PVD COATING SERVICE PROVIDERS, 2010
Table 46 : CERAMICS DEPOSITED BY CVD
Table 47 : TYPICAL CERAMIC CVD COATINGS, PROCESS GASES AND DEPOSITION TEMPERATURES
Table 48 : CCVD MATERIALS, SUBSTRATES AND APLICAITONS
Table 49 : KEY TECHNICAL ADVANTAGES OF THE CVD PROCESS
Table 50 : KEY TECHNICAL DISADVANTAGES OF THE CVD PROCESS
Table 51 : REPRESENTATIVE CVD CERAMIC COATINGS
Table 52 : OVERVIEW OF CURRENT/EMERGING CUTTING TOOL CVD APPLICATIONS
Table 53 : RECENT DEVELOPMENTS IN CERAMIC CVD COATING
Table 54 : LEADING WORLDWIDE MANUFACTURERS OF CVD EQUIPMENT
Table 55 : LEADING WORLDWIDE CVD SERVICE PROVIDERS
Table 56 : NORTH AMERICAN CERAMIC CVD COATING SERVICE MARKETS BY APPLICATION, THROUGH 2016
Table 57 : NORTH AMERICAN MARKET FOR CERAMIC CVD TOOL INSERT COATINGS, THROUGH 2016
Table 58 : NORTH AMERICAN MARKET FOR CERAMIC CVD WEAR-RESISTANT AND OTHER INDUSTRIALCOATING APPLICATIONS, THROUGH 2016
Table 59 : NORTH AMERICAN MARKET FOR CERAMIC CVD AUTOMOTIVE COMPONENT COATINGS, THROUGH 2016
Table 60 : NORTH AMERICAN MARKET FOR CERAMIC CVD AEROSPACE COATINGS, THROUGH 2016
Table 61 : NORTH AMERICAN MARKET FOR CERAMIC CVD MEDICAL DEVICE COATINGS, THROUGH 2016
Table 62 : MARKET SHARE OF CERAMIC CVD COATING SERVICE PROVIDERS, 2010
Table 63 : TEMPERATURE DROP USING COATED HEADERS IN AUTO ENGINES
Table 64 : APPLICATIONS OF SOL GEL FILMS AND COATINGS
Table 65 : NORTH AMERICAN COMPANIES PROVIDING CERAMIC COATING SERVICES USING SPRAYING, DIPPING, SOL GEL, LASER AND IONIC BEAM TECHNIQUES
Table 66 : NORTH AMERICAN MARKET FOR OTHER TYPES OF COATING SERVICE BY APPLICATION, THROUGH 2016

List of Figures

Summary Figure : MARKET SHARE OF NORTH AMERICAN HIGH-PERFORMANCE CERAMIC COATING TECHNOLOGIES, 2010-2016
Summary Figure :
Figure 1 : SHARE OF NORTH AMERICAN HIGH-PERFORMANCE CERAMIC COATING SERVICE MARKET SEGMENTS, 2010–2016
Figure 2 : PLASMA SPRAY COATING TECHNIQUE
Figure 3 : SCHEMATIC OF HVOF
Figure 4 : SHARE OF NORTH AMERICAN CERAMIC THERMAL SPRAY COATING SERVICE MARKET SUBSEGMENTS, 2010-2016
Figure 5 : A COMPARISON OF THE TRS OF UNCOATED AND COATED CARBIDE AS MEASURED BY THE THREE-POINT BEND TEST ON 0.20 BY 0.20 BY 0.75 IN. SPECIMENS
Figure 6 : SHARE OF NORTH AMERICAN CERAMIC THERMAL SPRAY COATING SERVICE MARKET SUBSEGMENTS, 2010–2016
Figure 7 : SUMMARY OF CARBIDE METALCUTTING GRADE DEVELOPMENT
Figure 8 : SHARE OF NORTH AMERICAN CERAMIC CVD COATING SERVICE MARKET SEGMENTS, 2010-2016
Figure 9 : SHARE OF NORTH AMERICAN CERAMIC COATINGS MARKET USING SPRAYING/ DIPPING, SOL GEL, MICRO OXIDATION AND LASER-ASSISTED TECHNIQUES BY APPLICATION, 2010-2016