High Performance Ceramic Coatings: Markets and Technologies

Published by: BCC Research

Published: Feb. 1, 2010 - 236 Pages

Table of Contents

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

SUMMARY TABLE NORTH AMERICAN MARKET FOR HIGH-PERFORMANCE CERAMIC COATINGS BY TYPE OF COATING TECHNOLOGY, THROUGH 2014 ($ MILLIONS)

SUMMARY FIGURE MARKET SHARE OF NORTH AMERICAN HIGH-PERFORMANCE CERAMIC COATING TECHNOLOGIES, 2008-2014 (% TOTAL MARKET)

CHAPTER THREE: 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 2014 ($ MILLIONS)

FIGURE 1 SHARE OF NORTH AMERICAN HIGH-PERFORMANCE CERAMIC COATING SERVICE MARKET SEGMENTS, 2008-2014 (%)

INTERNATIONAL COMPETITION

CHAPTER FOUR: TECHNOLOGY OVERVIEW

MATERIAL TYPES AND PROPERTIES

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

COATING TECHNIQUES

GENERAL APPLICATIONS

TABLE 5 LEADING APPLICATIONS OF DEPOSITION BY INDUSTRY

TABLE 6 TYPICAL COATINGS AND APPLICATIONS

CHAPTER FIVE: THERMAL SPRAY

THERMAL SPRAY TECHNIQUES

COMBUSTION WIRE THERMAL SPRAY PROCESS

Features and Benefits

Typical Applications

COMBUSTION POWDER THERMAL SPRAY PROCESS

TABLE 7 CERAMIC MATERIALS USED IN THE POWDER FLAME 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)

FIGURE 2 PLASMA SPRAY COATING TECHNIQUE

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

FIGURE 3 SCHEMATIC OF HVOF

TABLE 8 PROPERTIES OF HVOF CARBIDE COATINGS

Features and Benefits

Typical Applications

COLD SPRAY PROCESS

JET KOTE PROCESS

DETONATION THERMAL SPRAY PROCESS

PROCESS COMPARISONS

TABLE 9 COMPARISON OF THERMAL SPRAY PROCESSES

APPLICATIONS

AIRCRAFT ENGINES AND AEROSPACE

Gas Turbine Engines

TABLE 10 DETONATION GUN APPLICATIONS IN THE GAS TURBINE ENGINE

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

TABLE 11 THERMAL SPRAY COATINGS FOR FRPS

RECENT DEVELOPMENTS

TABLE 12 RECENT DEVELOPMENTS IN THERMAL SPRAY COATINGS

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

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

ACQUISITIONS, MERGERS AND OTHER BUSINESS RELATIONSHIPS

TABLE 18 ACQUISITIONS, MERGERS AND OTHER BUSINESS RELATIONS IN THE THERMAL-SPRAY INDUSTRY SINCE 1990

NORTH AMERICAN MARKETS

TURBINE ENGINES OEM AND OVERHAUL

Aircraft Engines

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)

Land-Based Turbines

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)

WEAR RESISTANT PARTS AND INDUSTRIAL APPLICATIONS

TABLE 26 TOTAL NORTH AMERICAN EXPENDITURES ON THERMAL SPRAY CERAMIC COATING OF WEAR RESISTANT PARTS AND INDUSTRIAL APPLICATIONS, THROUGH 2014 ($ MILLIONS)

AUTOMOTIVE AND DIESEL ENGINES

TABLE 27 NORTH AMERICAN EXPENDITURES ON THERMAL SPRAY CERAMIC COATINGS IN AUTOMOTIVE AND DIESEL ENGINES, THROUGH 2014 ($ MILLIONS)

MEDICAL

TABLE 28 TOTAL NORTH AMERICAN EXPENDITURES ON THERMAL SPRAY CERAMIC COATINGS FOR MEDICAL APPLICATIONS, THROUGH 2014 ($ MILLIONS)

HEAT EXCHANGERS AND HIGH TEMPERATURE

OTHER APPLICATIONS

MARKET AND MARKET SHARES

TABLE 29 NORTH AMERICAN CERAMIC THERMAL SPRAY COATING MARKET, THROUGH 2014 ($ MILLIONS)

FIGURE 4 SHARE OF NORTH AMERICAN CERAMIC THERMAL-SPRAY COATING SERVICE MARKET SUB-SEGMENTS, 2008-2014

MARKET SHARE OF COMPANIES

TABLE 30 MARKET SHARE OF THERMAL SPRAY COATING SERVICE PROVIDERS (%)

CHAPTER SIX: PHYSICAL VAPOR DEPOSITION (PVD)

BASIC PRINCIPLES

PVD MATERIALS

TABLE 31 REPRESENTATIVE FILMS DEPOSITED BY PVD

TABLE 32 REPRESENTATIVE PVD SURFACE COATINGS FOR ABRASION AND CORROSION RESISTANT APPLICATIONS

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

TABLE 33 TYPES OF PHYSICAL VAPOR DEPOSITION PROCESSES

PVD BY EVAPORATION

Evaporation Sources

Evaporation Deposition Processes

Thermal Evaporation

Electron-beam Evaporation

PVD ARC PROCESS

PVD BY SPUTTERING

Sputtering Sources and Processes

TABLE 34 BASIC SPUTTERING SOURCES AND PROCESSES

Direct Current (DC) Diode Sputtering

Triode Sputtering

Radio Frequency (RF) Sputtering

Magnetron Sputtering

TABLE 35 COMPARISON OF MAGNETRON SPUTTERING METHODS FOR DEPOSITING SIO2

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

TABLE 36 CERAMIC PVD APPLICATIONS

TOOLS

TABLE 37 PROPERTIES OF UNCOATED AND TIN COATED HSS

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

TABLE 38 PROPERTIES AND APPLICATION OF VARIOUS BALZERS BALINIT THIN FILM WEAR-RESISTANT COATINGS

TURBINE VANES AND BLADES

RECENT DEVELOPMENTS

TABLE 39 RECENT DEVELOPMENTS IN PVD

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

TABLE 40 LEADING NORTH AMERICAN COMPANIES MANUFACTURING PVD SYSTEMS AND/OR PROVIDING SERVICES

NORTH AMERICAN MARKETS

TABLE 41 NORTH AMERICAN HIGH-PERFORMANCE CERAMIC PVD COATING MARKET, THROUGH 2014 ($ MILLIONS)

FIGURE 6 SHARE OF NORTH AMERICAN CERAMIC THERMAL-SPRAY COATING SERVICE MARKET SUBSEGMENTS, 2008-2014 (% OF TOTAL THERMAL SPRAY MARKET)

TOOLS

TABLE 42 NORTH AMERICAN MARKET FOR CERAMIC PVD TOOL COATINGS, THROUGH 2014 ($ MILLIONS)

INDUSTRIAL SERVICES

TABLE 43 NORTH AMERICAN MARKET FOR CERAMIC COATINGS FOR AUTOMOTIVE, AEROSPACE AND WEAR-RESISTANT APPLICATIONS, THROUGH 2014 ($ MILLIONS)

MEDICAL

TABLE 44 NORTH AMERICAN MARKET FOR CERAMIC PVD MEDICAL DEVICE COATINGS, 2008-2014 ($ MILLIONS)

MARKET SHARE OF COMPANIES

TABLE 45 MARKET SHARE OF CERAMCI PVD COATING SERVICE PROVIDERS, 2008 (%)

CHAPTER SEVEN: CHEMICAL VAPOR DEPOSITION (CVD)

BASIC PRINCIPLE

CVD MATERIALS

TABLE 46 CERAMICS DEPOSITED BY CVD

CVD TECHNIQUES

TABLE 47 TYPICAL CERAMIC CVD COATINGS, PROCESS GASES AND DEPOSITION TEMPERATURES

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)

TABLE 48 CCVD MATERIALS, SUBSTRATES AND APLICAITONS

ADVANTAGES AND DISADVANTAGES OF CVD

TABLE 49 KEY TECHNICAL ADVANTAGES OF THE CVD PROCESS

TABLE 50 KEY TECHNICAL DISADVANTAGES OF THE CVD PROCESS

CVD APPLICATIONS

TABLE 51 REPRESENTATIVE CVD CERAMIC COATINGS

CUTTING TOOLS

FIGURE 7 SUMMARY OF CARBIDE METALCUTTING GRADE DEVELOPMENT

TABLE 52 OVERVIEW OF CURRENT/EMERGING CUTTING TOOL CVD APPLICATIONS

INDUSTRIAL APPLICATIONS

AEROSPACE

HIGH-TEMPERATURE APPLICATIONS

FOULING-RESISTANT CERAMIC MEMBRANES

NEW DEVELOPMENTS

TABLE 53 RECENT DEVELOPMENTS IN CERAMIC CVD COATING

PIEZOELECTRIC/ELECTROSTRICTIVE STRUCTURE AND METHOD FOR MANUFACTURING THE SAME

INDUSTRY STRUCTURE

LEADING CVD SYSTEMS MANUFACTURERS

TABLE 54 LEADING WORLDWIDE MANUFACTURERS OF CVD EQUIPMENT

LEADING CVD SERVICE PROVIDERS

TABLE 55 LEADING WORLDWIDE CVD SERVICE PROVIDERS

NORTH AMERICAN MARKET

TABLE 56 NORTH AMERICAN CERAMIC CVD COATING SERVICE MARKETS BY APPLICATION, THROUGH 2014 ($ MILLIONS)

FIGURE 8 SHARE OF NORTH AMERICAN CERAMIC CVD COATING SERVICE MARKET SEGMENTS, 2008-2014 (% OF TOTAL CVD COATING MARKET)

TOOLS

TABLE 57 NORTH AMERICAN MARKET FOR CERAMIC CVD TOOL INSERT COATINGS, THROUGH 2014 ($ MILLIONS)

WEAR-RESISTANT AND INDUSTRIAL APPLICATIONS

TABLE 58 NORTH AMERICAN MARKET FOR CERAMIC CVD WEAR RESISTANT AND OTHER INDUSTRIALCOATING APPLICATIONS, THROUGH 2014 ($ MILLIONS)

AUTOMOTIVE

TABLE 59 NORTH AMERICAN MARKET FOR CERAMIC CVD AUTOMOTIVE COMPONENT COATINGS, THROUGH 2014 ($ MILLIONS)

AIRCRAFT AND AEROSPACE

TABLE 60 NORTH AMERICAN MARKET FOR CERAMIC CVD AEROSPACE COATINGS, THROUGH 2014 ($ MILLIONS)

MEDICAL

TABLE 61 NORTH AMERICAN MARKET FOR CERAMIC CVD MEDICAL DEVICE COATINGS, THROUGH 2014 ($ MILLIONS)

MARKET SHARE OF COMPANIES

TABLE 62 MARKET SHARE OF CERAMIC CVD COATING SERVICE PROVIDERS (%)

CHAPTER EIGHT: OTHER COATING TECHNIQUES

SPRAYING, BRUSH PAINTING, AND DIPPING

SPRAYING

Metallic Ceramic Coating

Ceramic Coating

Thermal Barrier Coating

Dry-Film Coating

TABLE 63 TEMPERATURE DROP USING COATED HEADERS IN AUTO ENGINES (°F)

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

TABLE 64 APPLICATIONS OF SOL GEL FILMS AND COATINGS

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

TABLE 65 NORTH AMERICAN COMPANIES PROVIDING CERAMIC COATING SERVICES USING SPRAYING, DIPPING, SOL GEL, LASER AND IONIC BEAM TECHNIQUES

NORTH AMERICAN MARKET

SPRAYING/BRUSH PAINTING/DIPPING

TABLE 66 NORTH AMERICAN CERAMIC CVD COATING “OTHER” SERVICE MARKETS BY APPLICATION, THROUGH 2014 ($ MILLIONS)

FIGURE 9 SHARE OF NORTH AMERICAN CERAMIC COATINGS MARKET USING SPRAYING/DIPPING, SOL GEL, MICRO OXIDATION AND LASER-ASSISTED TECHNIQUES BY APPLICATION, 2008-2014 (%)

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 (%)

Abstract

• 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.

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