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High-Performance Ceramic Coatings: Markets and Technologies

High-Performance Ceramic Coatings: Markets and Technologies

The North American market for high-performance ceramic coatings totaled $1.2 billion in 2014. This market is expected to reach nearly $1.9 billion in 2020 from $1.3 billion in 2015 increasing at a compound annual growth rate of 7.8% for the period 2015-2020.

This report provides:
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.
Information regarding the current size and future growth of the markets for ceramic thermal spray, PVD, CVD and other coatings services.
Analyses of North American market trends, with data from 2014 and 2015, and projections of CAGRs through 2020.
A technology overview, including material types, properties and applications for ceramic coatings.
Analysis of domestic competition among companies within each of the ceramic coating service segments.
Profiles of equipment manufacturers, service providers and suppliers of consumables among ceramic thermal spray, PVD, CVD and other coating techniques.


SCOPE AND FORMAT

This BCC Research study was conducted with a global perspective in terms of materials and their applications. Market projections have been conducted for North America, while all market table values are in 2014 U.S. dollars.

The report provides business planners and managers with an improved understanding of the direction and impact of 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 their 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 Research believes that the qualitative and quantitative judgments embodied in this report are a valuable contribution to the current knowledge of high-performance ceramic coatings.

CHAPTER 1 INTRODUCTION
STUDY GOALS AND OBJECTIVES
REASONS FOR CONDUCTING THE STUDY
CONTRIBUTIONS OF THE STUDY AND INTENDED AUDIENCE
SCOPE AND FORMAT
METHODOLOGY AND INFORMATION SOURCES
ANALYST'S CREDENTIALS
RELATED BCC RESEARCH REPORTS
BCC RESEARCH WEBSITE
DISCLAIMER
CHAPTER 2 EXECUTIVE SUMMARY
SUMMARY TABLE NORTH AMERICAN MARKET FOR HIGH-PERFORMANCE CERAMIC COATINGS BY TYPE, THROUGH 2020 ($ MILLIONS)
SUMMARY FIGURE NORTH AMERICAN MARKET SHARE FOR HIGH-PERFORMANCE
CERAMIC COATING TECHNOLOGIES BY TYPE, 2014 TO 2020 (%)
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 2020 ($ MILLIONS)
FIGURE 1 NORTH AMERICAN MARKET SHARE FOR HIGH-PERFORMANCE CERAMIC COATING BY APPLICATION SEGMENTS, 2014 TO 2020 (%)
CHAPTER 4 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 AND 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 5 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
FIGURE 2 PLASMA SPRAY COATING TECHNIQUE
Features and Benefits
Typical Applications
Supersonic Induction Plasma Torch
Controlled-Atmosphere Plasma Spray Coatings
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
SUSPENSION 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 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
TABLE 11 THERMAL SPRAY COATINGS FOR FRPS
RECENT DEVELOPMENTS
TABLE 12 RECENT DEVELOPMENTS IN THERMAL SPRAY COATINGS TECHNOLOGIES
Pressure Based Liquid Feed System for Suspension Plasma Spray Coatings
MATERIALS
Preparation of Amorphous Mixed Metal Oxides and Their Use as Feedstocks in Thermal Spray Coating
APPLICATIONS
Rough Dense Ceramic Sealing Surface in Turbomachines
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 NORTH AMERICAN MARKET FOR THERMAL SPRAY CERAMIC COATING OF AIRCRAFT GAS TURBINE PARTS BY ENGINE TYPE, THROUGH 2020 ($ MILLIONS)
TABLE 20 NORTH AMERICAN SHIPMENTS OF TURBOFAN, TURBOPROP AND TURBOSHAFT ENGINES, THROUGH 2020 (UNITS)
TABLE 21 COST OF AIRCRAFT ENGINE COATING SERVICES, THROUGH 2020 ($ MILLIONS)
TABLE 22 NORTH AMERICAN MARKET FOR AIRCRAFT GAS TURBINE ENGINE OVERHAUL, THROUGH 2020 ($ MILLIONS/UNITS/$)
Land-Based Turbines
TABLE 23 NORTH AMERICAN MARKET FOR THERMAL SPRAY CERAMIC COATING OF LARGE LAND-BASED TURBINE PARTS, THROUGH 2020 ($ MILLIONS)
TABLE 24 COST OF NEW LARGE LAND-BASED TURBINE COATING SERVICES, THROUGH 2020 ($ MILLIONS)
TABLE 25 COST OF LARGE LAND-BASED TURBINE REFURBISHMENT COATING SERVICES, THROUGH 2020 ($ MILLIONS)
WEAR-RESISTANT PARTS AND INDUSTRIAL APPLICATIONS
TABLE 26 NORTH AMERICAN MARKET FOR THERMAL SPRAY CERAMIC COATING OF WEAR-RESISTANT PARTS AND INDUSTRIAL APPLICATIONS, THROUGH 2020 ($ MILLIONS)
AUTOMOTIVE AND DIESEL ENGINES
TABLE 27 NORTH AMERICAN MARKET FOR THERMAL SPRAY CERAMIC COATINGS IN AUTOMOTIVE AND DIESEL ENGINES, THROUGH 2020 ($ MILLIONS)
MEDICAL
TABLE 28 NORTH AMERICAN MARKET FOR THERMAL SPRAY CERAMIC COATINGS FOR MEDICAL APPLICATIONS, THROUGH 2020 ($ MILLIONS)
HEAT EXCHANGERS AND HIGH TEMPERATURE
OTHER APPLICATIONS
MARKET AND MARKET SHARES
TABLE 29 NORTH AMERICAN MARKET FOR CERAMIC THERMAL SPRAY COATING BY SEGMENT, THROUGH 2020 ($ MILLIONS)
FIGURE 4 NORTH AMERICAN MARKET SHARE FOR CERAMIC THERMAL SPRAY COATING SERVICE BY SEGMENTS, 2014 TO 2020 (%)
MARKET SHARE OF COMPANIES
TABLE 30 NORTH AMERICAN MARKET SHARE FOR THERMAL SPRAY COATING SERVICE PROVIDERS, 2014 (%)
CHAPTER 6 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
Co-sputtering
Reactive Sputtering
COMPARISON OF EVAPORATION AND SPUTTERING
MULTICHAMBER SYSTEM
PVD ADVANTAGES AND LIMITATIONS
ADVANTAGES:
DISADVANTAGES:
PVD APPLICATIONS
TABLE 36 CERAMIC PVD APPLICATIONS
TOOLS
TABLE 37 PROPERTIES OF UNCOATED AND TIN-COATED HIGH SPEED STEEL (HSS)
FIGURE 5 COMPARISON OF THE TRS OF UNCOATED AND COATED CARBIDE* (TRS MPA)
TABLE 38 PROPERTIES AND APPLICATION OF VARIOUS BALZERS BALINIT
THIN-FILM WEAR-RESISTANT COATINGS
TURBINE VANES AND BLADES
OTHER AEROSPACE APPLICATIONS
RECENT DEVELOPMENTS
TABLE 39 RECENT DEVELOPMENTS IN PVD
TECHNOLOGIES
Deposition of LiCoO2
APPLICATIONS
Thin Film Capacitors on Metal Foils and Methods of Manufacturing Same
Synthesis of Advanced Scintillators via Vapor Deposition Techniques
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 MARKET FOR HIGH-PERFORMANCE CERAMIC PVD COATING BY SEGMENT, THROUGH 2020 ($ MILLIONS)
FIGURE 6 NORTH AMERICAN MARKET SHARE FOR CERAMIC THERMAL SPRAY
COATING SERVICE BY SEGMENT, 2014 TO 2020 (%)
TOOLS
TABLE 42 NORTH AMERICAN MARKET FOR CERAMIC PVD TOOL COATINGS, THROUGH 2020 ($ MILLIONS)
INDUSTRIAL SERVICES
TABLE 43 NORTH AMERICAN MARKET FOR CERAMIC COATINGS FOR AUTOMOTIVE, AEROSPACE AND WEAR-RESISTANT APPLICATIONS, THROUGH 2020 ($ MILLIONS)
MEDICAL
TABLE 44 NORTH AMERICAN MARKET FOR CERAMIC PVD MEDICAL DEVICE COATINGS, THROUGH 2020 ($ MILLIONS)
MARKET SHARE OF COMPANIES
TABLE 45 NORTH AMERICAN MARKET SHARE FOR CERAMIC PVD COATING BY SERVICE PROVIDERS, 2014 (%)
CHAPTER 7 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 APPLICATIONS 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 CUTTING TOOL CVD APPLICATIONS
INDUSTRIAL APPLICATIONS
AEROSPACE
HIGH-TEMPERATURE APPLICATIONS
FOULING-RESISTANT CERAMIC MEMBRANES
NEW DEVELOPMENTS
TABLE 53 RECENT DEVELOPMENTS IN CERAMIC CVD COATING
CVD COATED POLYCRYSTALLINE C-BN CUTTING TOOL
INDUSTRY STRUCTURE
LEADING CVD SYSTEMS MANUFACTURERS
TABLE 54 LEADING GLOBAL MANUFACTURERS OF CVD EQUIPMENT
LEADING CVD SERVICE PROVIDERS
TABLE 55 LEADING GLOBAL CVD SERVICE PROVIDERS
NORTH AMERICAN MARKET
TABLE 56 NORTH AMERICAN MARKET FOR CERAMIC CVD COATING SERVICE BY APPLICATION, THROUGH 2020 ($ MILLIONS)
FIGURE 8 NORTH AMERICAN MARKET SHARE FOR CERAMIC CVD COATING SERVICE BY APPLICATION, 2014 TO 2020 (%)
TOOLS
TABLE 57 NORTH AMERICAN MARKET FOR CERAMIC CVD TOOL INSERT COATINGS, THROUGH 2020 ($ MILLIONS)
WEAR-RESISTANT AND INDUSTRIAL APPLICATIONS
TABLE 58 NORTH AMERICAN MARKET FOR CERAMIC CVD WEAR-RESISTANT AND OTHER INDUSTRIAL COATING APPLICATIONS, THROUGH 2020 ($ MILLIONS)
AUTOMOTIVE
TABLE 59 NORTH AMERICAN MARKET FOR CERAMIC CVD AUTOMOTIVE COMPONENT COATINGS, THROUGH 2020 ($ MILLIONS)
AIRCRAFT AND AEROSPACE
TABLE 60 NORTH AMERICAN MARKET FOR CERAMIC CVD AEROSPACE COATINGS, THROUGH 2020 ($ MILLIONS)
MEDICAL
TABLE 60 NORTH AMERICAN MARKET FOR CERAMIC CVD AEROSPACE COATINGS, THROUGH 2020 ($ MILLIONS)
MARKET SHARE OF COMPANIES
TABLE 62 NORTH AMERICAN MARKET SHARE FOR CERAMIC CVD COATING SERVICE PROVIDERS, 2014 (%)
CHAPTER 8 OTHER COATING TECHNIQUES
SPRAYING, BRUSH PAINTING AND DIPPING
SPRAYING
Metallic Ceramic Coating
Advantages of Metallic Ceramic Coating
Ceramic Coating
Why Ceramic Coatings for Automotive Finishing Needs?
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 Coatings
ELECTRODEPOSITION
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
MOLECULAR BEAM EPITAXY
AEROSOL DEPOSITION
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 MARKET FOR OTHER TYPES OF COATING SERVICE BY APPLICATION, THROUGH 2020 ($ MILLIONS)
FIGURE 9 NORTH AMERICAN MARKET SHARE FOR CERAMIC COATINGS USING SPRAYING/DIPPING, SOL-GEL, MICRO OXIDATION AND LASER-ASSISTED TECHNIQUES BY APPLICATION, 2014 TO 2020 (%)
MARKET SHARE OF COMPANIES
CHAPTER 9 COMPANY PROFILES
PROFILES OF NORTH AMERICAN COMPANIES INVOLVED IN CERAMIC
COATINGS AS EQUIPMENT MANUFACTURERS, SUPPLIERS OF CONSUMABLES, COATING SERVICE PROVIDERS AND USERS
A&A COATINGS INC.
ACCUWRIGHT INDUSTRIES INC.
ADVANCED CUTTING TOOLS INC.
AERO TURBINE INC.
AESTHETIC FINISHERS INC.
AIR PRODUCTS & CHEMICALS INC.
ALPHA TECH COATINGS INC.
AMERICAN ROLLER CO.
APPLIED MATERIALS
APS MATERIALS
AREMCO PRODUCTS INC.
ASB INDUSTRIES INC.
ADVANCED CERAMIC COATING INC.
CERAM-KOTE COATINGS INC.
CETEK LIMITED
CHEMAT TECHNOLOGY INC.
CHROMALLOY GAS TURBINE LLC
CHROMALLOY NEW YORK
CINCINNATI THERMAL SPRAY
COTRONICS CORP.
CURTISS-WRIGHT SURFACE TECHNOLOGIES
CVD EQUIPMENT CORP.
DATEC COATING CORP.
DENTON VACUUM
ELLISON SURFACE TECHNOLOGIES
ENVIRONMENTAL ABRASIVES
EUTECTIC CORP.
EXLINE INC.
FFWD CONNECTION
FLAME SPRAY COATING CO. INC.
GENERAL ELECTRIC CO.
GENERAL MAGNAPLATE CORP.
GRENCO ENERGY SERVICES
HAYDEN CORP.
HEANY INDUSTRIES INC.
HFW INDUSTRIES INC.
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.
KENNAMETAL STELLITE COATINGS
MER CORP.
NANOPHASE TECHNOLOGIES INC.
NGIMAT CO.
NORTHWEST METTECH CORP.
OERLIKON BALZERS COATING USA INC.
OERLIKON METCO (U.S.) INC.
PETERS PERFORMANCE CERAMIC COATING
PLASMA COATINGS INC.
PLASMA TECHNOLOGY INC.
PRATT & WHITNEY
PRAXAIR SURFACE TECHNOLOGIES INC.
PRAXAIR SURFACE TECHNOLOGIES/TAFA INC.
PRECISION COATINGS INC.
PRIEST ELECTRIC
PROFESSIONAL CRYOGENIC METALLURGY & COATINGS LLC (PCMC)
PROSTRIP PROFESSIONAL METAL REFINISHING INC.
PROGRESSIVE SURFACE INC.
RAM PRO-LINE
SAINT GOBAIN CERAMIC MATERIALS
SANDVIK INC.
SECO TOOLS INC.
SOLAR ATMOSPHERES INC.
SPECIALIZED CERAMIC AND POWDER COATINGS
SPIRE CORP.
ST. LOUIS METALLIZING CO.
STARFIRE SYSTEMS INC.
PERFORMANCE ROD & CUSTOM
SYLCO INC.
SWAIN TECHNOLOGY INC.
TECH LINE COATINGS INC.
TECHNETICS GROUP
THIN AIR POWERSPORTS
ULTRAMET
ULVAC TECHNOLOGIES INC.
UTC AEROSPACE SYSTEMS
WHITE ENGINEERING SURFACES CORP.

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