High-Performance Ceramic Coatings: Markets and Technologies

 Published On: Jan, 2016 |    No of Pages: 179 |  Published By: BCC Research-JT Gabrielsen Consulting LLC Research | Format: PDF
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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.

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 2014, significant changes have taken place in the ceramic coating service industry. In view of these changes, BCC Research determined there was a need to update the previous editionís 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 of ceramic thermal spray, PVD, CVD and other coating techniques.
-Identify the users of ceramic coating services.

REASONS FOR CONDUCTING 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, as well as ceramic components.

High-performance ceramic coatings are a special class of ceramics because of their form and the preparation techniques required. However, their uses are diverse, and they exploit a 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 longer than the life of uncoated inserts. This, in turn, has reduced the cost of cutting tool inserts, while increasing productivity. Similarly, use of ceramic-coated components for aircraft turbine engines has resulted in construction of large aircraft. Currently, auto enthusiasts are coating certain components to improve auto engine performance. In addition, ceramic coatings have made it possible for certain large machine components to be repaired in situ.

CONTRIBUTIONS OF THE STUDY AND INTENDED AUDIENCE
This new BCC Research study provides an in-depth analysis of the materials, applications, economics, current markets and trends, and players in ceramics coatings. Forecasts are provided for each major market segment through 2020. 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 Research 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 types 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 at 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 repairing and refurbishing aircraft engines.
-Producers of automotive and diesel engines.
-Shops providing coating services to racing cars 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 l capital companies and financial institutions interested in new and attractive
investments.

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.

METHODOLOGY AND INFORMATION SOURCES
This report is an updated version of a report originally published in 2004 and subsequently updated in 2007, 2010, 2012 and 2014. Both primary and secondary research methodologies were used to prepare 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 coating service providers and end-users were contacted to evaluate current and future demands for these coatings.

More than 200 industry contacts assisted BCC Research in identifying and updating technologies and applications. In addition to using its in-house database on ceramic coatings, BCC Research conducted extensive Web searches to gather and analyze all pertinent information related to this study. Major technical and trade publications and conference proceedings on ceramic coatings were also used for this study.
Chapter- 1: INTRODUCTION - Complimentary     5 $0
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     2 $250
Table Summary : NORTH AMERICAN MARKET FOR HIGH-PERFORMANCE CERAMIC COATINGS BY TYPE, THROUGH 2020
Figure Summary : NORTH AMERICAN MARKET SHARE FOR HIGH-PERFORMANCE CERAMIC COATING TECHNOLOGIES BY TYPE, 2014 TO 2020

Chapter- 3: INDUSTRY OVERVIEW 3 $167
INDUSTRY STRUCTURE
TECHNICAL AND BUSINESS ISSUES
NORTH AMERICAN MARKETS

Chapter- 4: TECHNOLOGY OVERVIEW 8 $446
MATERIAL TYPES AND PROPERTIES
COATING TECHNIQUES
GENERAL APPLICATIONS

Chapter- 5: THERMAL SPRAY 46  $2563
THERMAL SPRAY TECHNIQUES
APPLICATIONS
RECENT DEVELOPMENTS
INDUSTRY STRUCTURE
NORTH AMERICAN MARKETS

Chapter- 6: PHYSICAL VAPOR DEPOSITION (PVD) 28     $1560
BASIC PRINCIPLES
PVD MATERIALS
PVD TECHNOLOGIES
PVD ADVANTAGES AND LIMITATIONS
PVD APPLICATIONS
RECENT DEVELOPMENTS
INDUSTRY STRUCTURE
NORTH AMERICAN MARKETS

Chapter- 7: CHEMICAL VAPOR DEPOSITION (CVD) 26     $1449
BASIC PRINCIPLE
CVD MATERIALS
CVD TECHNIQUES
CVD APPLICATIONS
NEW DEVELOPMENTS
INDUSTRY STRUCTURE
NORTH AMERICAN MARKET

Chapter- 8: OTHER COATING TECHNIQUES     22 $1226
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
MOLECULAR BEAM EPITAXY
AEROSOL DEPOSITION
INDUSTRY STRUCTURE
NORTH AMERICAN MARKET

Chapter- 9: COMPANY PROFILES  39  $2173
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, THROUGH 2020
Table 1 : NORTH AMERICAN MARKET FOR HIGH-PERFORMANCE CERAMIC COATINGS, BY APPLICATION SEGMENT, THROUGH 2020
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
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 GAS TURBINE ENGINES
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 : NORTH AMERICAN MARKET FOR THERMAL SPRAY CERAMIC COATING OF AIRCRAFT GAS TURBINE PARTS BY ENGINE TYPE, THROUGH 2020
Table 20 : NORTH AMERICAN SHIPMENTS OF TURBOFAN, TURBOPROP AND TURBOSHAFT ENGINES, THROUGH 2020
Table 21 : COST OF AIRCRAFT ENGINE COATING SERVICES, THROUGH 2020
Table 22 : NORTH AMERICAN MARKET FOR AIRCRAFT GAS TURBINE ENGINE OVERHAUL, THROUGH 2020
Table 23 : NORTH AMERICAN MARKET FOR THERMAL SPRAY CERAMIC COATING OF LARGE LAND-BASED TURBINE PARTS, THROUGH 2020
Table 24 : COST OF NEW LARGE LAND-BASED TURBINE COATING SERVICES, THROUGH 2020
Table 25 : COST OF LARGE LAND-BASED TURBINE REFURBISHMENT COATING SERVICES, THROUGH 2020
Table 26 : NORTH AMERICAN MARKET FOR THERMAL SPRAY CERAMIC COATING OF WEAR-RESISTANT PARTS AND INDUSTRIAL APPLICATIONS, THROUGH 2020
Table 27 : NORTH AMERICAN MARKET FOR THERMAL SPRAY CERAMIC COATINGS IN AUTOMOTIVE AND DIESEL ENGINES, THROUGH 2020
Table 28 : NORTH AMERICAN MARKET FOR THERMAL SPRAY CERAMIC COATINGS FOR MEDICAL APPLICATIONS, THROUGH 2020
Table 29 : NORTH AMERICAN MARKET FOR CERAMIC THERMAL SPRAY COATING BY SEGMENT, THROUGH 2020
Table 30 : NORTH AMERICAN MARKET SHARE FOR THERMAL SPRAY COATING SERVICE PROVIDERS, 2014
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 MARKET FOR HIGH-PERFORMANCE CERAMIC PVD COATING BY SEGMENT, THROUGH 2020
Table 42 : NORTH AMERICAN MARKET FOR CERAMIC PVD TOOL COATINGS, THROUGH 2020
Table 43 : NORTH AMERICAN MARKET FOR CERAMIC COATINGS FOR AUTOMOTIVE, AEROSPACE AND WEAR-RESISTANT APPLICATIONS, THROUGH 2020
Table 44 : NORTH AMERICAN MARKET FOR CERAMIC PVD MEDICAL DEVICE COATINGS, THROUGH 2020
Table 45 : NORTH AMERICAN MARKET SHARE FOR CERAMIC PVD COATING BY SERVICE PROVIDERS, 2014
Table 46 : CERAMICS DEPOSITED BY CVD
Table 47 : TYPICAL CERAMIC CVD COATINGS, PROCESS GASES AND DEPOSITION TEMPERATURES
Table 48 : CCVD MATERIALS, SUBSTRATES AND APPLICATIONS
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 CUTTING TOOL CVD APPLICATIONS
Table 53 : RECENT DEVELOPMENTS IN CERAMIC CVD COATING
Table 54 : LEADING GLOBAL MANUFACTURERS OF CVD EQUIPMENT
Table 55 : LEADING GLOBAL CVD SERVICE PROVIDERS
Table 56 : NORTH AMERICAN MARKET FOR CERAMIC CVD COATING SERVICE BY APPLICATION, THROUGH 2020
Table 57 : NORTH AMERICAN MARKET FOR CERAMIC CVD TOOL INSERT COATINGS, THROUGH 2020
Table 58 : NORTH AMERICAN MARKET FOR CERAMIC CVD WEAR-RESISTANT AND OTHER INDUSTRIAL COATING APPLICATIONS, THROUGH 2020
Table 59 : NORTH AMERICAN MARKET FOR CERAMIC CVD AUTOMOTIVE COMPONENT COATINGS, THROUGH 2020
Table 60 : NORTH AMERICAN MARKET FOR CERAMIC CVD AEROSPACE COATINGS, THROUGH 2020
Table 61 : NORTH AMERICAN MARKET FOR CERAMIC CVD MEDICAL DEVICE COATINGS, THROUGH 2020
Table 62 : NORTH AMERICAN MARKET SHARE FOR CERAMIC CVD COATING SERVICE PROVIDERS, 2014
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 2020

List of Figures

Summary Figure : NORTH AMERICAN MARKET SHARE FOR HIGH-PERFORMANCE CERAMIC COATING TECHNOLOGIES BY TYPE, 2014 TO 2020
Figure 1 : NORTH AMERICAN MARKET SHARE FOR HIGH-PERFORMANCE CERAMIC COATING BY APPLICATION SEGMENTS, 2014 TO 2020
Figure 2 : PLASMA SPRAY COATING TECHNIQUE
Figure 3 : SCHEMATIC OF HVOF
Figure 4 : NORTH AMERICAN MARKET SHARE FOR CERAMIC THERMAL SPRAY COATING SERVICE BY SEGMENTS, 2014 TO 2020
Figure 5 : COMPARISON OF THE TRS OF UNCOATED AND COATED CARBIDE*
Figure 6 : NORTH AMERICAN MARKET SHARE FOR CERAMIC THERMAL SPRAY COATING SERVICE BY SEGMENT, 2014 TO 2020
Figure 7 : SUMMARY OF CARBIDE METALCUTTING GRADE DEVELOPMENT
Figure 8 : NORTH AMERICAN MARKET SHARE FOR CERAMIC CVD COATING SERVICE BY APPLICATION, 2014 TO 2020
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

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