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High Performance Ceramic Coatings: Markets and Technologies

BCC Research
February 1, 2010
236 Pages - SKU: WA2610236

Abstract Table of Contents Related Reports

REPORT HIGHLIGHTS:

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
Market projections for ceramic coatings in all the major applications, including data for 2008, estimates for 2009, and 5-year forecasts, with compound annual growth rates (CAGRs), through 2014
Profiles of current industry players, including suppliers of equipment, consumables, coating service providers, and users
A review of the economic/market opportunities for industry participants and new entrants.

CHAPTER ONE: INTRODUCTION: STUDY GOALS AND OBJECTIVES; REASONS FOR DOING THE STUDY; INTENDED AUDIENCE; SCOPE OF REPORT; METHODOLOGY AND INFORMATION SOURCES; AUTHOR’S CREDENTIALS; RELATED BCC REPORTS; BCC ONLINE SERVICES; DISCLAIMER
CHAPTER TWO: EXECUTIVE SUMMARY
CHAPTER THREE: INDUSTRY OVERVIEW: INDUSTRY STRUCTURE; TECHNICAL AND BUSINESS ISSUES; NORTH AMERICAN MARKETS; INTERNATIONAL COMPETITION
CHAPTER FOUR: TECHNOLOGY OVERVIEW: MATERIAL TYPES AND PROPERTIES; COATING TECHNIQUES; GENERAL APPLICATIONS
CHAPTER FIVE: THERMAL SPRAY: THERMAL SPRAY TECHNIQUES; COMBUSTION WIRE THERMAL SPRAY PROCESS; Features and Benefits; Typical Applications; COMBUSTION POWDER THERMAL SPRAY PROCESS; Features and Benefits; Typical Applications; ELECTRIC ARC WIRE THERMAL SPRAY PROCESS; Features and Benefits; Typical Applications; PLASMA THERMAL SPRAY PROCESS; Plasma Thermal Spray Process (Continued); Plasma Thermal Spray Process (Continued); Features and Benefits; Typical Applications; Supersonic Induction Plasma Torch; Controlled-Atmosphere Plasma Spray Coatings; Features and Benefits; Typical Applications; HVOF THERMAL SPRAY PROCESS; Features and Benefits; Typical Applications; COLD SPRAY PROCESS; JET KOTE PROCESS; DETONATION THERMAL SPRAY PROCESS; PROCESS COMPARISONS; APPLICATIONS; AIRCRAFT ENGINES AND AEROSPACE; Gas Turbine Engines; LAND-BASED GAS TURBINES; AUTOMOTIVE COMPONENTS; Engine Components; Exhaust Manifolds; DIESEL ENGINES; HEAT EXCHANGERS AND BOILERS; HIGH-TEMPERATURE CORROSION RESISTANT APPLICATIONS; WEAR RESISTANT AND INDUSTRIAL APPLICATIONS; MEDICAL; OTHER EMERGING APPLICATIONS AND COMPOSITIONS; RECENT DEVELOPMENTS; METHOD FOR PREPARING AND ULTRASONICALLY TESTING A THERMAL-SPRAY COATED ARTICLE; THERMAL SPRAY COATING OF POROUS NANOSTRUCTURED CERAMIC FEEDSTOCK; THERMAL SPRAYING POWDER; FORMATION OF ELECTROCONDUCTIVE LAYER ON ALUMINUM ELECTRODE SUPPORT BAR; CVT HOUSING WITH WEAR-RESISTANT BORE; THERMAL COATED PISTON RING; INSULATING SUBSTRATE AND SEMICONDUCTOR DEVICE HAVING A THERMALLY SPRAYED CIRCUIT PATTERN; INDUSTRY STRUCTURE; NORTH AMERICAN COMPANIES; ACQUISITIONS, MERGERS AND OTHER BUSINESS RELATIONSHIPS; NORTH AMERICAN MARKETS; TURBINE ENGINES OEM AND OVERHAUL; Aircraft Engines; Land-Based Turbines; WEAR RESISTANT PARTS AND INDUSTRIAL APPLICATIONS; AUTOMOTIVE AND DIESEL ENGINES; MEDICAL; HEAT EXCHANGERS AND HIGH TEMPERATURE; OTHER APPLICATIONS; MARKET AND MARKET SHARES; MARKET SHARE OF COMPANIES
CHAPTER SIX: PHYSICAL VAPOR DEPOSITION (PVD): BASIC PRINCIPLES; PVD MATERIALS; TITANIUM NITRIDE COATING (TIN); TITANIUM CARBO NITRIDE COATING (TICN); TITANIUM ALUMINUM NITRIDE COATING (TIALN); TITANIUM DIBORIDE COATING (TIB2); TIALN-X; CHROMIUM NITRIDE COATING (CRN); SUPER-R COATING; ZIRCONIUM NITRIDE COATING (ZRN); PVD TECHNOLOGIES; PVD BY EVAPORATION; Evaporation Sources; Evaporation Deposition Processes; Thermal Evaporation; Electron-beam Evaporation; PVD ARC PROCESS; PVD BY SPUTTERING; Sputtering Sources and Processes; Direct Current (DC) Diode Sputtering; Triode Sputtering; Radio Frequency (RF) Sputtering; Magnetron Sputtering; Linear Magnetron Sputtering; Unbalanced Magnetron Sputtering; Ion Beam Sputtering; Sputter Ion Plating (SIP) Process; Cosputtering; Reactive Sputtering; COMPARISON OF EVAPORATION AND SPUTTERING; MULTICHAMBER SYSTEM; PVD ADVANTAGES AND LIMITATIONS; PVD APPLICATIONS; TOOLS; TURBINE VANES AND BLADES; RECENT DEVELOPMENTS; METHOD TO PREVENT LOW TEMPERATURE DEGRADATION OF ZIRCONIA; CERAMIC COATINGS FOR INSULATING MODULAR FUEL CELL CASSETTES IN A SOLID-OXIDE FUEL CELL STACK; THERMAL BARRIER COATING RESISTANT TO PENETRATION BY ENVIRONMENTAL CONTAMINANTS; OXIDATION BARRIER COATINGS FOR SILICON BASED CERAMICS; INDUSTRY STRUCTURE; NORTH AMERICAN COMPANIES; NORTH AMERICAN MARKETS; TOOLS; INDUSTRIAL SERVICES; MEDICAL; MARKET SHARE OF COMPANIES
CHAPTER SEVEN: CHEMICAL VAPOR DEPOSITION (CVD): BASIC PRINCIPLE; CVD MATERIALS; CVD TECHNIQUES; BASIC THERMAL CVD PROCESS; Metallo-Organic CVD (MOCVD); Atmospheric Pressure CVD; Low-Pressure CVD; PLASMA-ASSISTED CVD; DC Plasma Method; RF Induction Plasma; Microwave Plasma Torch; Cathodic-arc Plasma Deposition; High-energy Intensified Plasma-assisted Processing; (HEIPAP); COMBUSTION CHEMICAL VAPOR DEPOSITON (CCVD); ADVANTAGES AND DISADVANTAGES OF CVD; CVD APPLICATIONS; CUTTING TOOLS; INDUSTRIAL APPLICATIONS; AEROSPACE; HIGH-TEMPERATURE APPLICATIONS; FOULING-RESISTANT CERAMIC MEMBRANES; NEW DEVELOPMENTS; PIEZOELECTRIC/ELECTROSTRICTIVE STRUCTURE AND METHOD FOR MANUFACTURING THE SAME; INDUSTRY STRUCTURE; LEADING CVD SYSTEMS MANUFACTURERS; LEADING CVD SERVICE PROVIDERS; NORTH AMERICAN MARKET; TOOLS; WEAR-RESISTANT AND INDUSTRIAL APPLICATIONS; AUTOMOTIVE; AIRCRAFT AND AEROSPACE; MEDICAL; MARKET SHARE OF COMPANIES
CHAPTER EIGHT: OTHER COATING TECHNIQUES: SPRAYING, BRUSH PAINTING, AND DIPPING; SPRAYING; Metallic Ceramic Coating; Ceramic Coating; Thermal Barrier Coating; Dry-Film Coating; PAINTING WITH A BRUSH; DIPPING; REPCOAT PROCESS; COATING UTILITIES; High-Temperature and Corrosion-Resistant Coatings; High Temperature Insulative Coating; CEMENTATION; PACK CEMENTATION; Fluidized-Bed Cementation Process; Vapor-Stream Cementation; SOL GEL PROCESSING; DATEC PROCESS; USING LASERS FOR COATING; PULSED LASER DEPOSITION (PLD); LASER ASSISTED ATMOSPHERIC PLASMA SPRAYING; QQC PROCESS; ION BEAM-ASSISTED DEPOSITION (IBAD); ION BEAM SURFACE TREATMENT (IBEST); ION BEAM ENHANCED DEPOSITION (IBED); MICRODISCHARGE DEPOSITION; MICROPLASMIC COATING; INDUSTRY STRUCTURE; NORTH AMERICAN COMPANIES; NORTH AMERICAN MARKET; SPRAYING/BRUSH PAINTING/DIPPING; MARKET SHARE OF COMPANIES
CHAPTER NINE: COMPANY PROFILES: PROFILES OF NORTH AMERICAN COMPANIES INVOLVED IN CERAMIC COATINGS AS EQUIPMENT MANUFACTURERS, SUPPLIERS OF CONSUMABLES, COATING SERVICE PROVIDERS AND USERS; A&A COMPANY, INC; ACCESSORIES PLUS; ACCUWRIGHT INDUSTRIES, INC.; ADVANCED CUTTING TOOLS, INC.; AERO TURBINE, INC.; AESTHETIC FINISHERS INC.; AIR PRODUCTS & CHEMICALS, INC.; ALPHA TECH COATINGS (ATC), INC.; AMERICAN ROLLER CO.; APPLIED MATERIALS; APS MATERIALS; AREMCO PRODUCTS INC; ASB INDUSTRIES; BENDER MACHINE CO.; CERAMIC COATING, INC.; CETEK LIMITED; CHEMAT TECHNOLOGY INC.; CHROMALLOY GAS TURBINE LLC; CHROMALLOY NEW YORK; CINCINNATI THERMAL SPRAY; COTRONICS CORP.; CVD EQUIPMENT CORP.; DATEC COATING CORP.; DENTON VACUUM; ELLISON SURFACE TECHNOLOGIES; ENGELHARD SURFACE TECHNOLOGIES/BASF; ENVIRONMENTAL ABRASIVES; EUTECTIC CORP.; EXLINE INC.; FREECOM INC.; F.W. GARTNER THERMAL SPRAYING CO.; FFWD CONNECTION; FLAME SPRAY COATING CO. INC.; FLAME SPRAY INC.; GENERAL ELECTRIC CO.; GENERAL MAGNAPLATE CORP.; GOLD STAR COATINGS/BALZERS; GRENCO INDUSTRIES, LTD.; GSEM, INC.; HAYDEN CORP.; HEANY INDUSTRIES, INC.; HFW INDUSTRIES, INC.; HIGH PERFORMANCE COATINGS; HITEMCO; HONEYWELL AEROSPACE; HOWMET CASTING SPECIAL PRODUCTS; HOWMET CASTINGS THERMATECH COATINGS; HOWMET TURBINE COMPONENTS COATINGS; INDUSTRIAL GRINDING; INDUSTRIAL MACHINE & MFG., LTD.; INFRAMAT CORP.; INGERSOLL CUTTING TOOL COMPANY; IONBOND INC.; JET-HOT COATINGS; KENNAMETAL, INC.; MER CORP.; NGIMAT CO.; MICROPLASMIC CORPORATION; MUSCLE SHOALS MINERALS; NANOPHASE TECHNOLOGIES, INC.; NATIONAL THERMOSPRAY INC.; NORTHWEST METTECH CORP.; OERLIKON USA; PETERS PERFORMANCE CERAMIC COATING; PLASMA COATINGS, INC; PLASMA TECHNOLOGY, INC.; PRATT & WHITNEY; PRAXAIR SPECIALTY CERAMICS, INC.; PRAXAIR SURFACE TECHNOLOGIES, INC.; PRAXAIR SURFACE TECHNOLOGIES COATING DIVISION; PRAXAIR TAFA; PRECISION COATINGS, INC.; PRIEST ELECTRIC; PROFESSIONAL CRYOGENIC METALLURGY & COATINGS,; LLC (PCMC); PROFESSIONAL METAL REFINISHING, INC.; PROGRESSIVE TECHNOLOGIES, INC.; QQC/TURCHAN TECHNOLOGIES GROUP, INC.; RAM COATING SERVICES LLC; RAM PRO LINE; SAINT GOBAIN GRAINS AND POWDERS; SANDVIK, INC.; SECO TOOLS, INC.; SERMATECH INTERNATIONAL INC.; SOLAR ATMOSPHERES INC.; SPECIALIZED CERAMIC AND POWDER COATINGS; SPIRE CORPORATION; ST. LOUIS METALIZING CO.; STARFIRE SYSTEMS INC.; STEEL PLANT EQUIPMENT CORP.; STELLITE COATINGS; STREETROD STUFF, INC.; SULZER METCO (U.S.), INC.; SYLCO INC.; SWAIN TECHNOLOGY INC.; TECH LINE COATINGS, INC.; TECHNETICS CORP.; THIN AIR POWERSPORTS; TURBINE COMPONENTS SERVICES; ULTRAMET; ULVAC TECHNOLOGIES INC.; VEECO INSTRUMENTS INC; WHITE ENGINEERING SURFACES CORPORATION; WHITE ENGINEERING SURFACES CORPORATION
LIST OF TABLES: SUMMARY TABLE NORTH AMERICAN MARKET FOR HIGH-; PERFORMANCE CERAMIC COATINGS BY TYPE OF COATING; TECHNOLOGY, THROUGH 2014 ($ MILLIONS); TABLE 1 NORTH AMERICAN MARKET FOR HIGH PERFORMANCE; CERAMIC COATINGS, BY APPLICATION SEGMENT, THROUGH 2014; ($ MILLIONS); 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 2014 ($ MILLIONS); TABLE 20 NORTH AMERICAN SHIPMENTS OF; TURBOFAN, TURBOPROP, AND TURBOSHAFT; ENGINES, THROUGH 2014 (NUMBER OF ENGINES); TABLE 21 COST OF AIRCRAFT ENGINE COATING SERVICES,; THROUGH 2014 ($ MILLIONS); TABLE 22 NORTH AMERICAN AIRCRAFT GAS TURBINE ENGINE; OVERHAUL MARKET THROUGH 2014 ($ MILLIONS); TABLE 23 TOTAL NORTH AMERICAN EXPENDITURES ON THERMAL; SPRAY CERAMIC COATING OF LARGE LAND-BASED TURBINE; PARTS, THROUGH 2014 ($ MILLIONS); TABLE 24 COST OF NEW LARGE LAND-BASED TURBINE COATING; SERVICES, THROUGH 2014 ($ MILLIONS); TABLE 25 COST OF LARGE LAND-BASED TURBINE; REFURBISHMENT COATING SERVICES, THROUGH 2014 ($; MILLIONS); TABLE 26 TOTAL NORTH AMERICAN EXPENDITURES ON THERMAL; SPRAY CERAMIC COATING OF WEAR RESISTANT PARTS AND; INDUSTRIAL APPLICATIONS, THROUGH 2014 ($ MILLIONS); TABLE 27 NORTH AMERICAN EXPENDITURES ON THERMAL SPRAY; CERAMIC COATINGS IN AUTOMOTIVE AND DIESEL ENGINES,; THROUGH 2014 ($ MILLIONS); TABLE 28 TOTAL NORTH AMERICAN EXPENDITURES ON THERMAL; SPRAY CERAMIC COATINGS FOR MEDICAL APPLICATIONS,; THROUGH 2014 ($ MILLIONS); TABLE 29 NORTH AMERICAN CERAMIC THERMAL SPRAY COATING; MARKET, THROUGH 2014 ($ MILLIONS); TABLE 30 MARKET SHARE OF THERMAL SPRAY COATING SERVICE; PROVIDERS (%); 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 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 2014 ($ MILLIONS); TABLE 42 NORTH AMERICAN MARKET FOR CERAMIC PVD TOOL; COATINGS, THROUGH 2014 ($ MILLIONS); TABLE 43 NORTH AMERICAN MARKET FOR CERAMIC COATINGS; FOR AUTOMOTIVE, AEROSPACE AND WEAR-RESISTANT; APPLICATIONS, THROUGH 2014 ($ MILLIONS); TABLE 44 NORTH AMERICAN MARKET FOR CERAMIC PVD MEDICAL; DEVICE COATINGS, 2008-2014 ($ MILLIONS); TABLE 45 MARKET SHARE OF CERAMCI PVD COATING SERVICE; PROVIDERS, 2008 (%); 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 2014 ($ MILLIONS); TABLE 57 NORTH AMERICAN MARKET FOR CERAMIC CVD TOOL; INSERT COATINGS, THROUGH 2014 ($ MILLIONS); TABLE 58 NORTH AMERICAN MARKET FOR CERAMIC CVD WEAR; RESISTANT AND OTHER INDUSTRIALCOATING APPLICATIONS,; THROUGH 2014 ($ MILLIONS); TABLE 59 NORTH AMERICAN MARKET FOR CERAMIC CVD; AUTOMOTIVE COMPONENT COATINGS, THROUGH 2014 ($; MILLIONS); TABLE 60 NORTH AMERICAN MARKET FOR CERAMIC; CVD AEROSPACE COATINGS, THROUGH 2014 ($; MILLIONS); TABLE 61 NORTH AMERICAN MARKET FOR CERAMIC CVD MEDICAL; DEVICE COATINGS, THROUGH 2014 ($ MILLIONS); TABLE 62 MARKET SHARE OF CERAMIC CVD COATING SERVICE; PROVIDERS (%); TABLE 63 TEMPERATURE DROP USING COATED HEADERS IN AUTO; ENGINES (°F); 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 CERAMIC CVD COATING “OTHER”; SERVICE MARKETS BY APPLICATION, THROUGH 2014 ($; MILLIONS)
LIST OF FIGURES: SUMMARY FIGURE MARKET SHARE OF NORTH AMERICAN HIGH-; PERFORMANCE CERAMIC COATING TECHNOLOGIES, 2008-2014 (%; TOTAL MARKET); FIGURE 1 SHARE OF NORTH AMERICAN HIGH-PERFORMANCE; CERAMIC COATING SERVICE MARKET SEGMENTS, 2008-2014; FIGURE 2 PLASMA SPRAY COATING TECHNIQUE; FIGURE 3 SCHEMATIC OF HVOF; FIGURE 4 SHARE OF NORTH AMERICAN CERAMIC THERMAL-SPRAY; COATING SERVICE MARKET SUB-SEGMENTS, 2008-2014; FIGURE 5 A COMPARISON OF THE TRS OF UNCOATED AND COATED; CARBIDE AS MEASURED BY THE THREE-POINT BEND TEST ON; 0.2 X 0.2 X 0.75 INCH SPECIMENS; FIGURE 6 SHARE OF NORTH AMERICAN CERAMIC THERMAL-SPRAY; COATING SERVICE MARKET SUBSEGMENTS, 2008-2014 (% OF; TOTAL THERMAL SPRAY MARKET); FIGURE 7 SUMMARY OF CARBIDE METALCUTTING GRADE; DEVELOPMENT; FIGURE 8 SHARE OF NORTH AMERICAN CERAMIC CVD COATING; SERVICE MARKET SEGMENTS, 2008-2014 (% OF TOTAL CVD; COATING MARKET); FIGURE 9 SHARE OF NORTH AMERICAN CERAMIC COATINGS; MARKET USING SPRAYING/DIPPING, SOL GEL, MICRO OXIDATION; AND LASER-ASSISTED TECHNIQUES BY APPLICATION, 2008-2014 (%)

High Performance Ceramic Coatings: Markets and Technologies

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