This report provides an overview of the various advanced ceramic and nanosized ceramic powders, their production technologies, and applications. Includes forecasts through 2016.
REPORT HIGHLIGHTS
- The U.S. consumed more than $3.1 billion worth of advanced and nanoscale ceramic powders in 2010. Consumption is projected to increase to nearly $3.4 billion in 2011 and $5.4 billion in 2016, a projected compound annual growth rate (CAGR) of 9.9% between 2011 and 2016.
- Advanced ceramic powders account for the bulk of the market (i.e. 83% in 2010), with sales of $2.5 billion in 2010, increasing to $4 billion by 2016, for a CAGR of 8.3%.
- Nanoscale powders are expected to increase their market share steadily, reaching a 24% market share by 2016. Its market was worth $528 million in 2010. This should increase at a CAGR of 16.4% to reach $1.2 billion in 2016.
REPORT SCOPE
INTRODUCTION
Advanced ceramic materials are a mature technology with a very broad base of current and potential applications and a growing list of material compositions. Advanced ceramics are inorganic, nonmetallic materials with combinations of fine–scale microstructures, purity, complex compositions and crystal structures, and accurately controlled additives. Such materials require a level of processing science and engineering far beyond that used in making conventional ceramics. These new generations of high–performance materials have already reached a U.S. market of several billion dollars. Collectively, they represent an enabling technology whose continued development is critical to advances in a host of new high–technology applications, ranging from modern microelectronics to superconductors and nanotechnology.
The outstanding properties possessed by advanced ceramics are achieved through special compositions and microstructures that require very careful control throughout the successive stages of ceramic processing. These stages are: powder synthesis, powder sizing, rheology control, consolidation and forming processes, sintering, final machining, and inspection.
Ceramic powder is a necessary ingredient for most of the structural ceramics, electronic ceramics, ceramic coatings, and chemical processing and environmental related ceramics. For most advanced ceramic components, starting powder is a crucial factor. The performance characteristics of a ceramic component are greatly influenced by precursor powder characteristics. Among the most important are the powder’s chemical purity, particle size distribution, and the manner in which the powders are packed in the green body before sintering.
Powders of narrow size distribution can be compacted into ordered arrays and, when in the submicron region, these powders are sintered at reduced temperatures. Consequently, in the processing of advanced ceramics, there is a growing need to develop synthetic techniques capable of producing submicron, chemically pure powders with a tailored size distribution. However, the cost is again the factor since the new synthetic processing techniques are comparatively more expensive than the currently established powder manufacturing methods.
Nanoceramic powders constitute an important segment of the whole nanostructured materials market. These powders are used in an array of applications from microelectronics, optical, chemical, environmental, and magnetic recording.
STUDY GOALS AND OBJECTIVES
BCC published the first report on this subject, entitled Advanced Ceramic Powders, in 1994. Since then, many new developments have occurred, especially in the availability of large quantities of nanoceramic powders, as well as the increased usage of these powders.
BCC has updated the original report several times in order to reflect timely developments in advanced and nanoceramic powders. The present report is the sixth updated edition of the 1994 study. Its objectives are to:
- Provide an overview of the various advanced ceramic and nanosized ceramic powders, their production technologies, and applications
- Identify the technological and business issues related to the commercial production and use of advanced ceramic and nanosized ceramic powders
- Determine the current size and future growth of the markets for oxide, carbide, nitride, and boride ceramic powders
- Determine the current size and future growth of the markets for nanosized ceramic powders
- Identify and profile suppliers of advanced ceramic and nanosized ceramic powders to the U.S. market
- Identify major user industries of advanced ceramic and nanosized ceramic powders
- Identify major issues related to the production and commercialization of advanced ceramic and nanosized ceramic powders
CONTRIBUTIONS Of THE STUDY
BCC’s technical and economic study covers the material types, synthesis techniques, production methods, current and emerging applications, suppliers, and trends in consumption of the various types of advanced ceramic and nanosized ceramic powders. Current size and future growth of the markets are estimated for the period 2010 through 2016. The report profiles commercially significant suppliers of advanced ceramic and nanosized ceramic powders to the U.S. market.
In particular, the term nanotechnology is used today to describe a wide range of new technologies and materials, not all of which are actually nanoscale. Some manufacturers have tacked the prefix “nano” onto their products and processes, whether or not they deal in nano–sized elements, in an attempt to boost customer or investor interest. Such hype inevitably carries with it the risk of a backlash, because it can create unrealistic expectations for nanotechnology. This report takes a realistic look at the nanoceramics field and tries to provide a road map to the technologies and applications that show the greatest commercial promise over the next 5 years.
SCOPE OF REPORTS
For each ceramic powder type, the report provides an analysis of material types in that category, processing technologies, properties, applications, suppliers, prices, and U.S. markets.
A technology review has been conducted on the current and emerging ceramic powder production technologies, such as carbothermal reduction, vapor–phase reaction, plasma processes, sol–gel techniques, and chemical techniques (including precipitation, hydrothermal process, emulsion process, laser synthesis, and self–propagating high–temperature synthesis [SHS]). Nanosized powders have been treated in a separate chapter since many nanosized powder synthesis technologies are common to different ceramic powders.
The qualitative and quantitative judgments embodied in this report are a valuable contribution to the current knowledge of advanced and nanosized ceramic powders, their processing techniques, applications, and markets. They should be useful to companies that are facing decisions about their strategies for expansion or entering new areas of business.
METHODOLOGY AND INFORMATION SOURCES
The findings of this report are based on information derived from interviews with many producers and potential producers of advanced ceramic powders and nanosized ceramic powders, industry experts, and those conducting research and development. In addition, many end users were contacted to evaluate the current and future demand for these materials. Secondary data were obtained from trade publications, technical journals, government statistics, and BCC databases.
With 2010 as a baseline, projections for each market segment were developed for 2011 through 2016. The projections are based on a combination of a consensus among the primary contacts combined with BCC’s understanding of the key market drivers and their impact from a historical and analytical perspective.
Unless otherwise noted, all dollar projections presented in this report are in 2010 constant dollars.
INTENDED AUDIENCE
This report is directed to the various types of companies that are interested in the developments of this field. These include:
- Companies involved in the development, manufacturing, and supplying of advanced materials.
- Manufacturers and suppliers of advanced ceramic raw materials.
Manufacturers and suppliers of advanced ceramic powders. - Companies involved in R&D and commercialization of nanosized ceramic powders.
- Companies involved in the development and manufacture of advanced ceramic components.
- Engine component manufacturers.
- Cutting tool insert manufacturers.
- Manufacturers of integrated circuits, piezoelectric elements, capacitors, ferrite magnets and magnetic cores, and superconductor wires.
- Suppliers and users of thermal spray powders.
- Manufacturers of wear parts and OEM suppliers.
- Manufacturers of ceramic catalysts, catalyst supports, and auto catalytic converters.
- Manufacturers of ceramic membranes and filters.
- Producers and users of chemical mechanical polishing (CMP) slurries.
- Producers of magnetic recording media.
- Producers of sunscreens.
- Chemical companies interested in diversification.
- Venture capital companies and financial institutions interested in new, attractive investments and acquisitions.
Table of Contents :
Chapter- 1: INTRODUCTION
STUDY GOALS AND OBJECTIVES
CONTRIBUTIONS OF THE STUDY
SCOPE OF REPORT
METHODOLOGY AND INFORMATION SOURCES
INTENDED AUDIENCE
ANALYST CREDENTIALS
RELATED BCC REPORTS
BCC ONLINE SERVICES
DISCLAIMER
Chapter- 2: EXECUTIVE SUMMARY 2
Table 0 : U.S. CONSUMPTION OF ADVANCED AND NANOSCALE CERAMIC POWDERS, THROUGH 2016
Figure 0 : U.S. CONSUMPTION OF ADVANCED AND NANOSIZED CERAMIC POWDERS, 2010-2016
Chapter- 3: OVERVIEW OF ADVANCED CERAMIC POWDERS 49
POWDER TYPES
POWDER SYNTHESIS TECHNIQUES
MATERIAL APPLICATIONS AND PROPERTIES
END–USER INDUSTRIES
OVERALL U.S. MARKET FOR ADVANCED AND NANOSCALE CERAMIC POWDERS
Table 20 : U.S. MARKETS FOR ADVANCED AND NANOSCALE CERAMIC POWDERS, THROUGH 2016
Figure 6 : U.S. MARKET FOR ADVANCED AND NANOSCALE CERAMIC POWDERS BY TYPE OF POWDER, THROUGH 2016
Table L-6 :
Figure 7 : U.S. MARKET FOR ADVANCED AND NANOSCALE CERAMIC POWDERS BY TYPE OF END–USE, THROUGH 2016
Table L-7 :
Chapter- 4: OXIDE POWDERS 32
SUMMARY
MATERIAL TYPES
SYNTHESIS AND POWDER PREPARATION
PROPERTIES
APPLICATIONS
SUPPLIERS
MARKETS
Chapter- 5: CARBIDE POWDERS 11
MATERIAL TYPES
SYNTHESIS AND POWDER PREPARATION
PROPERTIES
APPLICATIONS
SUPPLIERS
MARKETS
Chapter- 6: NITRIDE POWDERS 11
MATERIAL TYPES
SYNTHESIS AND POWDER PREPARATION
PROPERTIES
APPLICATIONS
SUPPLIERS
MARKETS
Chapter- 7: BORIDE POWDERS 5
MATERIAL TYPES
SYNTHESIS AND POWDER PREPARATION
PROPERTIES
APPLICATIONS
SUPPLIERS
MARKETS
Chapter- 8: NANOSCALE CERAMIC POWDERS 25
MATERIAL TYPES
PROPERTIES
FABRICATION OF NANOPOWDERS
APPLICATIONS
SUPPLIERS
MARKETS
Table 54 : U.S. MARKETS FOR CERAMIC NANOPOWDERS BY APPLICATIONS AND MATERIALS TYPES, THROUGH 2016
Figure 14 : CERAMIC NANOPOWDER MARKET SEGENTS, 2010-2016
Table L-14 :
Chapter- 9: APPENDIX 32
PROFILES OF NORTH AMERICAN COMPANIES AND INSTITUTIONS INVOLVED IN CERAMIC AND NANOCERAMIC POWDERS
List of Tables
Summary Table : U.S. CONSUMPTION OF ADVANCED AND NANOSCALE CERAMIC POWDERS, THROUGH 2016
Table 1 : COMMONLY USED ADVANCED CERAMIC MATERIAL FAMILIES
Table 2 : PROCESS STEPS TO PRODUCE ß–SIC VIA CARBOTHERMAL REDUCTION
Table 3 : PLASMA SYNTHESIS OF CERAMIC POWDERS
Table 4 : POWDER SYNTHESIS COMPARISON
Table 5 : POWDER PROCESSES FOR VARIOUS CERAMIC MATERIALS
Table 6 : CURRENT AND POTENTIAL USES FOR ADVANCED CERAMICS
Table 7 : CURRENT AND POTENTIAL APPLICATIONS OF ADVANCED STRUCTURAL CERAMICS
Table 8 : PROPERTIES OF COMMERCIAL ALUMINA SPECIFICATIONS
Table 9 : PROPERTIES OF NORZIDE YZ–110 TETRAGONAL ZIRCONIA POLYCRYSTALS
Table 10 : FRACTURE TOUGHNESS AND CRITICAL FLAW SIZES OF MONOLITHIC AND COMPOSITE CERAMICS MATERIALSa
Table 11 : PROPERTIES OF MONOLITHIC CERAMICS AND CERAMIC COMPOSITES
Table 12 : THERMAL CONDUCTIVITY OF VARIOUS ZIRCONIAS
Table 13 : HIGH–PERFORMANCE CERAMIC COATING MATERIALS AND GENERAL APPLICATIONS
Table 14 : REPRESENTATIVE FLAME AND PLASMA SPRAYED MATERIALS, MELTING OR SOFTENING TEMPERATURE, AND USES
Table 15 : CERAMIC INSULATORS AND THEIR PROPERTIES
Table 16 : CERAMIC SUBSTRATE PROPERTIES
Table 17 : CANDIDATE CERAMIC SUBSTRATE MATERIALS FOR ELECTRONICS
Table 18 : DIELECTRIC MATERIAL FOR MULTILAYER CERAMIC CAPACITOR
Table 19 : U.S. MARKETS FOR ADVANCED CERAMIC COMPONENTS, THROUGH 2016
Table 20 : U.S. MARKETS FOR ADVANCED AND NANOSCALE CERAMIC POWDERS, THROUGH 2016
Table 21 : STEPS TO SYNTHESIZE BaTiO3
Table 22 : MAJOR U.S. SUPPLIERS OF ADVANCED OXIDE CERAMIC POWDERS AND PRODUCTS
Table 23 : U.S. MARKETS FOR CERAMIC SUBSTRATES, INTEGRATED CIRCUITS, INSULATORS AND MCMS, THROUGH 2016
Table 24 : ALUMINA POWDER CONSUMPTION FOR ELECTRONIC APPLICATIONS, THROUGH 2016
Table 25 : U.S. MARKETS FOR ALUMINA POWDERS FOR STRUCTURAL APPLICATIONS, THROUGH 2016
Table 26 : U.S. MARKETS FOR ALUMINA POWDERS FOR THERMAL SPRAY APPLICATIONS, THROUGH 2016
Table 27 : U.S. MARKETS FOR OXIDE POWDERS FOR MEMBRANE APPLICATIONS, THROUGH 2016
Table 28 : U.S. MARKETS FOR OXIDE POWDERS FOR CERAMIC FILTERS THROUGH 2016
Table 29 : U.S. MARKETS FOR OXIDE POWDERS FOR CHEMICAL PROCESSING CATALYST SUPPORTS, THROUGH 2016
Table 30 : U.S. MARKETS FOR ALUMINA POWDERS FOR CHEMICAL PROCESSING APPLICATIONS, THROUGH 016
Table 31 : U.S. MARKETS FOR ALUMINA POWDERS FOR ADVANCED CERAMIC APPLICATIONS, THROUGH 2016
Table 32 : BERYLLIA POWDER CONSUMPTION FOR ELECTROCERAMIC APPLICATIONS, THROUGH 2016
Table 33 : U.S. MARKETS FOR ZIRCONIA POWDERS FOR ADVANCED CERAMIC APPLICATIONS, THROUGH 2016
Table 34 : U.S. MARKETS FOR CERAMIC CAPACITORS AND BARIUM TITANATE POWDERS, THROUGH 2016
Table 35 : U.S. MARKET FOR PIEZOELECTRIC CERAMIC ELEMENTS AND LEAD ZIRCONATE TITANATE POWDERS, THROUGH 2016
Table 36 : TITANATE POWDER CONSUMPTION FOR ADVANCED CERAMIC APPLICATIONS, THROUGH 2016
Table 37 : MARKET FOR CERAMIC PERMANENT MAGNETS, THROUGH 2016
Table 38 : U.S. SOFT FERRITES MARKETS, THROUGH 2016
Table 39 : U.S. CONSUMPTION OF HARD AND SOFT FERRITES, THROUGH 2016
Table 40 : U.S. CONSUMPTION OF SILICA POWDER FOR CATALYST SUPPORTS THROUGH 2016
Table 41 : MIXED OXIDE POWDER CONSUMPTION FOR ADVANCED CERAMIC APPLICATIONS, THROUGH 2016
Table 42 : U.S. MARKETS FOR OXIDE CERAMIC POWDERS, 2010 THROUGH 2016
Table 43 : MAJOR U.S. SUPPLIERS OF CARBIDE POWDERS FOR ADVANCED CERAMICS APPLICATIONS
Table 44 : U.S. MARKETS FOR CARBIDE POWDERS FOR ADVANCED CERAMIC APPLICATIONS, 2010 THROUGH 2016
Table 45 : MAJOR U.S. SUPPLIERS OF NITRIDE POWDERS FOR ADVANCED CERAMICS APPLICATIONS
Table 46 : U.S. MARKETS FOR SILICON NITRIDE POWDERS FOR ADVANCED CERAMIC APPLICATIONS, THROUGH 2016
Table 47 : U.S. MARKETS FOR ALUMINUM NITRIDE POWDERS, THROUGH 2016
Table 48 : U.S. MARKETS FOR BORON NITRIDE POWDERS FOR ADVANCED CERAMIC APPLICATIONS, THROUGH 2016
Table 49 : U.S. MARKETS FOR NITRIDE POWDERS FOR ADVANCED CERAMIC APPLICATIONS, THROUGH 2016
Table 50 : U.S. MARKETS FOR TITANIUM DIBORIDE POWDERS FOR ADVANCED CERAMIC APPLICATIONS, THROUGH 2016
Table 51 : SURFACE AREA OF SELECTED OXIDE POWDERS
Table 52 : POTENTIAL AND ACTUAL COMMERCIAL APPLICATIONS OF NANOCERAMIC POWDERS
Table 53 : SUPPLIERS OF NANOCERAMIC POWDERS AND PRODUCTS
Table 54 : U.S. MARKETS FOR CERAMIC NANOPOWDERS BY APPLICATIONS AND MATERIALS TYPES, THROUGH 2016
List of Figures
Summary Figure : U.S. CONSUMPTION OF ADVANCED AND NANOSIZED CERAMIC POWDERS, 2010-2016
Summary Figure : .
Figure 1 : SCHEMATIC DIAGRAM OF THERMAL REACTOR SYSTEM FOR PRODUCING CERAMIC POWDERS BY CVD
Figure 2 : SCHEMATIC OF A DC ARC PLASMA FURNACE DEVELOPED BY JAPAN’S NATIONAL RESEARCH INSTITUTE FOR METALS
Figure 3 : LOS ALAMOS RF PLASMA REACTOR
Figure 4 : PROCESS FLOWCHART FOR EMULSION PROCESS TO PRODUCE BARIUM TITANATE
Figure 5 : CERAMIC POWDER END–USER INDUSTRIES
Figure 6 : U.S. MARKET FOR ADVANCED AND NANOSCALE CERAMIC POWDERS BY TYPE OF POWDER, THROUGH 2016
Figure 7 : U.S. MARKET FOR ADVANCED AND NANOSCALE CERAMIC POWDERS BY TYPE OF END–USE, THROUGH 2016
Figure 8 : COMPARISON OF THE CONVENTIONAL SLURRY PROCESS FOR ß– AL2O3 PRODUCTION WITH THAT USING SOLUBLE ALKALI ADDITIVES
Figure 9 : SCHEMATIC FOR PRODUCTION OF PLASMA DISSOCIATED ZIRCONIA
Figure 10 : FLOW DIAGRAM OF A SPRAY ROASTER OF THE TYPE USED IN COMMERCIAL FERRITE POWDER PRODUCTION
Figure 11 : PROCESS FLOW DIAGRAM FOR A TUNGSTEN CARBIDE FACILITY
Figure 12 : SCHEMATIC OF PSI TECHNOLOGIES’ CONTINUOUS PROCESS FOR NANOSCALE POWDER SYNTHESIS
Figure 13 : SOL–GEL SYNTHESIS FLOW CHART
Figure 14 : CERAMIC NANOPOWDER MARKET SEGENTS, 2010-2016
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