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High-Performance Ceramic Coatings: Markets and Technologies

  • January 2016
  • -
  • BCC Research
  • -
  • 179 pages

This 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.

Use this report to:

Learn about the current and potential applications for high-performance ceramic coatings Identify the users of ceramic coating services
Receive information about the current and future market projections for ceramic coatings in their major applications
Gain insight into profiles of current industry players, including suppliers of equipment, consumables, coating service providers and users

Highlights

The north American market for high-performance ceramic coatings was $1.2 billion in 2014.
This market is expected to reach nearly $1.9 billion from $1.3 billion increasing at a compound annual growth rate of 7.8% for the period 2015-2020.
Thermal spray coatings will grow from $695.4 million in 2015 to $1.0 billion in 2020 increasing at a CAGR of 8.6% for the period 2015-2020.
Physical vapor deposition (PVD) as a segment will grow from $260.4 million in 2015 to $377.1 million in 2020 increasing at a CAGR of 7.7% for the period 2015-2020

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




Table Of Contents

High-Performance Ceramic Coatings: Markets and Technologies
HIGH-PERFORMANCE CERAMIC COATINGS: MARKETS AND TECHNOLOGIES
AVM015H
January 2016
Andrew McWilliams
CHAPTER 1 INTRODUCTION 2
STUDY GOALS AND OBJECTIVES 2
REASONS FOR CONDUCTING THE STUDY 2
CONTRIBUTIONS OF THE STUDY AND INTENDED AUDIENCE 3
SCOPE AND FORMAT 4
METHODOLOGY AND INFORMATION SOURCES 4
ANALYST'S CREDENTIALS 5
RELATED BCC RESEARCH REPORTS 5
BCC RESEARCH WEBSITE 6
DISCLAIMER 6
CHAPTER 2 EXECUTIVE SUMMARY 8
SUMMARY TABLE NORTH AMERICAN MARKET FOR HIGH-PERFORMANCE CERAMIC
COATINGS BY TYPE, THROUGH 2020 ($ MILLIONS) 8
SUMMARY FIGURE NORTH AMERICAN MARKET SHARE FOR HIGH-PERFORMANCE
CERAMIC COATING TECHNOLOGIES BY TYPE, 2014 TO 2020 (%) 8
CHAPTER 3 INDUSTRY OVERVIEW 11
INDUSTRY STRUCTURE 11
TECHNICAL AND BUSINESS ISSUES 11
NORTH AMERICAN MARKETS 12
TABLE 1 NORTH AMERICAN MARKET FOR HIGH-PERFORMANCE CERAMIC
COATINGS, BY APPLICATION SEGMENT, THROUGH 2020 ($ MILLIONS) 12
FIGURE 1 NORTH AMERICAN MARKET SHARE FOR HIGH-PERFORMANCE CERAMIC
COATING BY APPLICATION SEGMENTS, 2014 TO 2020 (%) 12
CHAPTER 4 TECHNOLOGY OVERVIEW 15
MATERIAL TYPES AND PROPERTIES 15
TABLE 2 HIGH-PERFORMANCE CERAMIC COATING MATERIALS AND GENERAL
APPLICATIONS 15
TABLE 3 REPRESENTATIVE FLAME AND PLASMA-SPRAYED MATERIALS, MELTING OR
SOFTENING TEMPERATURE AND USES 16
TABLE 4 PLASMA-SPRAYED CERAMIC COATING PROPERTIES 17
COATING TECHNIQUES 18
GENERAL APPLICATIONS 20
TABLE 5 LEADING APPLICATIONS OF DEPOSITION BY INDUSTRY 20
TABLE 6 TYPICAL COATINGS AND APPLICATIONS 21
CHAPTER 5 THERMAL SPRAY 24
THERMAL SPRAY TECHNIQUES 24
COMBUSTION WIRE THERMAL SPRAY PROCESS 24
Features and Benefits 25
Typical Applications 25
COMBUSTION POWDER THERMAL SPRAY PROCESS 25
TABLE 7 CERAMIC MATERIALS USED IN THE POWDER FLAME PROCESS 26
Features and Benefits 26
Typical Applications 26
ELECTRIC ARC WIRE THERMAL SPRAY PROCESS 27
Features and Benefits 27
Typical Applications 27
PLASMA THERMAL SPRAY PROCESS 28
FIGURE 2 PLASMA SPRAY COATING TECHNIQUE 29
Features and Benefits 31
Typical Applications 32
Supersonic Induction Plasma Torch 32
Controlled-Atmosphere Plasma Spray Coatings 33
HVOF THERMAL SPRAY PROCESS 34
FIGURE 3 SCHEMATIC OF HVOF 34
TABLE 8 PROPERTIES OF HVOF CARBIDE COATINGS 35
Features and Benefits 36
Typical Applications 36
COLD SPRAY PROCESS 36
JET KOTE PROCESS 37
DETONATION THERMAL SPRAY PROCESS 37
SUSPENSION SPRAY PROCESS 37
PROCESS COMPARISONS 38
TABLE 9 COMPARISON OF THERMAL SPRAY PROCESSES 38
APPLICATIONS 39
AIRCRAFT ENGINES AND AEROSPACE 39
Gas Turbine Engines 39
TABLE 10 DETONATION GUN APPLICATIONS IN GAS TURBINE ENGINES 41
LAND-BASED GAS TURBINES 45
AUTOMOTIVE COMPONENTS 45
Engine Components 46
Exhaust Manifolds 48
DIESEL ENGINES 48
HEAT EXCHANGERS AND BOILERS 49
HIGH-TEMPERATURE CORROSION-RESISTANT APPLICATIONS 49
WEAR-RESISTANT AND INDUSTRIAL APPLICATIONS 50
MEDICAL 50
OTHER EMERGING APPLICATIONS AND COMPOSITIONS 50
TABLE 11 THERMAL SPRAY COATINGS FOR FRPS 51
RECENT DEVELOPMENTS 52
TABLE 12 RECENT DEVELOPMENTS IN THERMAL SPRAY COATINGS 52
TECHNOLOGIES 52
Pressure Based Liquid Feed System for Suspension Plasma Spray
Coatings 52
MATERIALS 53
Preparation of Amorphous Mixed Metal Oxides and Their Use as
Feedstocks in Thermal Spray Coating 53
APPLICATIONS 53
Rough Dense Ceramic Sealing Surface in Turbomachines 53
INDUSTRY STRUCTURE 53
NORTH AMERICAN COMPANIES 54
TABLE 13 LEADING U.S. COMPANIES PROVIDING THERMAL SPRAY COATING
SERVICES FOR OEM PARTS 54
TABLE 14 NORTH AMERICAN CUSTOM/JOB SHOPS PROVIDING THERMAL SPRAY
COATING SERVICES 55
TABLE 15 LEADING U.S. COMPANIES PROVIDING THERMAL SPRAY COATING
CONSUMABLES 56
TABLE 16 U.S. COMPANIES SUPPLYING CONSUMABLES FOR NANOCERAMIC
COATINGS 56
TABLE 17 U.S. MANUFACTURERS OF PLASMA SPRAY EQUIPMENT 56
ACQUISITIONS, MERGERS AND OTHER BUSINESS RELATIONSHIPS 57
TABLE 18 ACQUISITIONS, MERGERS AND OTHER BUSINESS RELATIONS IN THE
THERMAL SPRAY INDUSTRY, SINCE 1990 57
NORTH AMERICAN MARKETS 58
TURBINE ENGINES OEM AND OVERHAUL 58
Aircraft Engines 58
TABLE 19 NORTH AMERICAN MARKET FOR THERMAL SPRAY CERAMIC COATING OF
AIRCRAFT GAS TURBINE PARTS BY ENGINE TYPE, THROUGH 2020 ($ MILLIONS) 58
TABLE 20 NORTH AMERICAN SHIPMENTS OF TURBOFAN, TURBOPROP AND
TURBOSHAFT ENGINES, THROUGH 2020 (UNITS) 59
TABLE 21 COST OF AIRCRAFT ENGINE COATING SERVICES, THROUGH 2020 ($
MILLIONS) 60
TABLE 22 NORTH AMERICAN MARKET FOR AIRCRAFT GAS TURBINE ENGINE
OVERHAUL, THROUGH 2020 ($ MILLIONS/UNITS/$) 61
Land-Based Turbines 61
TABLE 23 NORTH AMERICAN MARKET FOR THERMAL SPRAY CERAMIC COATING OF
LARGE LAND-BASED TURBINE PARTS, THROUGH 2020 ($ MILLIONS) 61
TABLE 24 COST OF NEW LARGE LAND-BASED TURBINE COATING SERVICES,
THROUGH 2020 ($ MILLIONS) 62
TABLE 25 COST OF LARGE LAND-BASED TURBINE REFURBISHMENT COATING
SERVICES, THROUGH 2020 ($ MILLIONS) 62
WEAR-RESISTANT PARTS AND INDUSTRIAL APPLICATIONS 63
TABLE 26 NORTH AMERICAN MARKET FOR THERMAL SPRAY CERAMIC COATING OF
WEAR-RESISTANT PARTS AND INDUSTRIAL APPLICATIONS, THROUGH 2020 ($
MILLIONS)
63
AUTOMOTIVE AND DIESEL ENGINES 64
TABLE 27 NORTH AMERICAN MARKET FOR THERMAL SPRAY CERAMIC COATINGS IN
AUTOMOTIVE AND DIESEL ENGINES, THROUGH 2020 ($ MILLIONS) 65
MEDICAL 65
TABLE 28 NORTH AMERICAN MARKET FOR THERMAL SPRAY CERAMIC COATINGS
FOR MEDICAL APPLICATIONS, THROUGH 2020 ($ MILLIONS) 66
HEAT EXCHANGERS AND HIGH TEMPERATURE 66
OTHER APPLICATIONS 66
MARKET AND MARKET SHARES 66
TABLE 29 NORTH AMERICAN MARKET FOR CERAMIC THERMAL SPRAY COATING BY
SEGMENT, THROUGH 2020 ($ MILLIONS) 67
FIGURE 4 NORTH AMERICAN MARKET SHARE FOR CERAMIC THERMAL SPRAY
COATING SERVICE BY SEGMENTS, 2014 TO 2020 (%) 67
MARKET SHARE OF COMPANIES 68
TABLE 30 NORTH AMERICAN MARKET SHARE FOR THERMAL SPRAY COATING
SERVICE PROVIDERS, 2014 (%) 69
CHAPTER 6 PHYSICAL VAPOR DEPOSITION (PVD) 71
BASIC PRINCIPLES 71
PVD MATERIALS 72
TABLE 31 REPRESENTATIVE FILMS DEPOSITED BY PVD 72
TABLE 32 REPRESENTATIVE PVD SURFACE COATINGS FOR ABRASION- AND
CORROSION-RESISTANT APPLICATIONS 73
TITANIUM NITRIDE COATING (TIN) 73
TITANIUM CARBO NITRIDE COATING (TICN) 73
TITANIUM ALUMINUM NITRIDE COATING (TIALN) 73
TITANIUM DIBORIDE COATING (TIB2) 74
TIALN-X 74
CHROMIUM NITRIDE COATING (CRN) 74
SUPER R COATING 74
ZIRCONIUM NITRIDE COATING (ZRN) 74
PVD TECHNOLOGIES 74
TABLE 33 TYPES OF PHYSICAL VAPOR DEPOSITION PROCESSES 75
PVD BY EVAPORATION 75
Evaporation Sources 76
Evaporation Deposition Processes 76
Thermal Evaporation 77
Electron-Beam Evaporation 77
PVD ARC PROCESS 78
PVD BY SPUTTERING 78
Sputtering Sources and Processes 79
TABLE 34 BASIC SPUTTERING SOURCES AND PROCESSES 79
Direct Current (DC) Diode Sputtering 79
Triode Sputtering 80
Radio Frequency (RF) Sputtering 80
Magnetron Sputtering 80
TABLE 35 COMPARISON OF MAGNETRON SPUTTERING METHODS FOR DEPOSITING
SIO2 81
Linear Magnetron Sputtering 81
Unbalanced Magnetron Sputtering 81
Ion Beam Sputtering 82
Sputter Ion Plating (SIP) Process 82
Co-sputtering 83
Reactive Sputtering 83
COMPARISON OF EVAPORATION AND SPUTTERING 84
MULTICHAMBER SYSTEM 85
PVD ADVANTAGES AND LIMITATIONS 85
ADVANTAGES: 85
DISADVANTAGES: 86
PVD APPLICATIONS 86
TABLE 36 CERAMIC PVD APPLICATIONS 86
TOOLS 87
TABLE 37 PROPERTIES OF UNCOATED AND TIN-COATED HIGH SPEED STEEL (HSS) 88
FIGURE 5 COMPARISON OF THE TRS OF UNCOATED AND COATED CARBIDE* (TRS
MPA) 88
TABLE 38 PROPERTIES AND APPLICATION OF VARIOUS BALZERS BALINIT THIN-FILM
WEAR-RESISTANT COATINGS 89
TURBINE VANES AND BLADES 91
OTHER AEROSPACE APPLICATIONS 91
RECENT DEVELOPMENTS 91
TABLE 39 RECENT DEVELOPMENTS IN PVD 92
TECHNOLOGIES 92
Deposition of LiCoO2 92
APPLICATIONS 92
Thin Film Capacitors on Metal Foils and Methods of Manufacturing
Same 92
Synthesis of Advanced Scintillators via Vapor Deposition Techniques 93
INDUSTRY STRUCTURE 93
NORTH AMERICAN COMPANIES 93
TABLE 40 LEADING NORTH AMERICAN COMPANIES MANUFACTURING PVD
SYSTEMS AND/OR PROVIDING SERVICES 94
NORTH AMERICAN MARKETS 94
TABLE 41 NORTH AMERICAN MARKET FOR HIGH-PERFORMANCE CERAMIC PVD
COATING BY SEGMENT, THROUGH 2020 ($ MILLIONS) 95
FIGURE 6 NORTH AMERICAN MARKET SHARE FOR CERAMIC THERMAL SPRAY
COATING SERVICE BY SEGMENT, 2014 TO 2020 (%) 95
TOOLS 96
TABLE 42 NORTH AMERICAN MARKET FOR CERAMIC PVD TOOL COATINGS,
THROUGH 2020 ($ MILLIONS) 96
INDUSTRIAL SERVICES 96
TABLE 43 NORTH AMERICAN MARKET FOR CERAMIC COATINGS FOR AUTOMOTIVE,
AEROSPACE AND WEAR-RESISTANT APPLICATIONS, THROUGH 2020 ($ MILLIONS) 97
MEDICAL 97
TABLE 44 NORTH AMERICAN MARKET FOR CERAMIC PVD MEDICAL DEVICE
COATINGS, THROUGH 2020 ($ MILLIONS) 98
MARKET SHARE OF COMPANIES 98
TABLE 45 NORTH AMERICAN MARKET SHARE FOR CERAMIC PVD COATING BY
SERVICE PROVIDERS, 2014 (%) 98
CHAPTER 7 CHEMICAL VAPOR DEPOSITION (CVD) 100
BASIC PRINCIPLE 100
CVD MATERIALS 101
TABLE 46 CERAMICS DEPOSITED BY CVD 101
CVD TECHNIQUES 103
TABLE 47 TYPICAL CERAMIC CVD COATINGS, PROCESS GASES AND DEPOSITION
TEMPERATURES 103
BASIC THERMAL CVD PROCESS 103
Metallo-Organic CVD (MOCVD) 104
Atmospheric Pressure CVD 104
Low-Pressure CVD 104
PLASMA-ASSISTED CVD 105
DC Plasma Method 105
RF Induction Plasma 106
Microwave Plasma Torch 106
Cathodic-Arc Plasma Deposition 106
High-Energy Intensified Plasma-Assisted Processing (HEIPAP) 107
COMBUSTION CHEMICAL VAPOR DEPOSITON (CCVD) 108
TABLE 48 CCVD MATERIALS, SUBSTRATES AND APPLICATIONS 109
ADVANTAGES AND DISADVANTAGES OF CVD 109
TABLE 49 KEY TECHNICAL ADVANTAGES OF THE CVD PROCESS 109
TABLE 50 KEY TECHNICAL DISADVANTAGES OF THE CVD PROCESS 110
CVD APPLICATIONS 110
TABLE 51 REPRESENTATIVE CVD CERAMIC COATINGS 110
CUTTING TOOLS 111
FIGURE 7 SUMMARY OF CARBIDE METALCUTTING GRADE DEVELOPMENT 112
TABLE 52 OVERVIEW OF CUTTING TOOL CVD APPLICATIONS 113
INDUSTRIAL APPLICATIONS 113
AEROSPACE 114
HIGH-TEMPERATURE APPLICATIONS 114
FOULING-RESISTANT CERAMIC MEMBRANES 114
NEW DEVELOPMENTS 114
TABLE 53 RECENT DEVELOPMENTS IN CERAMIC CVD COATING 115
CVD COATED POLYCRYSTALLINE C-BN CUTTING TOOL 115
INDUSTRY STRUCTURE 115
LEADING CVD SYSTEMS MANUFACTURERS 115
TABLE 54 LEADING GLOBAL MANUFACTURERS OF CVD EQUIPMENT 116
LEADING CVD SERVICE PROVIDERS 116
TABLE 55 LEADING GLOBAL CVD SERVICE PROVIDERS 117
NORTH AMERICAN MARKET 118
TABLE 56 NORTH AMERICAN MARKET FOR CERAMIC CVD COATING SERVICE BY
APPLICATION, THROUGH 2020 ($ MILLIONS) 118
FIGURE 8 NORTH AMERICAN MARKET SHARE FOR CERAMIC CVD COATING SERVICE
BY APPLICATION, 2014 TO 2020 (%) 119
TOOLS 119
TABLE 57 NORTH AMERICAN MARKET FOR CERAMIC CVD TOOL INSERT COATINGS,
THROUGH 2020 ($ MILLIONS) 120
WEAR-RESISTANT AND INDUSTRIAL APPLICATIONS 120
TABLE 58 NORTH AMERICAN MARKET FOR CERAMIC CVD WEAR-RESISTANT AND
OTHER INDUSTRIAL COATING APPLICATIONS, THROUGH 2020 ($ MILLIONS) 121
AUTOMOTIVE 121
TABLE 59 NORTH AMERICAN MARKET FOR CERAMIC CVD AUTOMOTIVE
COMPONENT COATINGS, THROUGH 2020 ($ MILLIONS) 122
AIRCRAFT AND AEROSPACE 122
TABLE 60 NORTH AMERICAN MARKET FOR CERAMIC CVD AEROSPACE COATINGS,
THROUGH 2020 ($ MILLIONS) 123
MEDICAL 123
TABLE 60 NORTH AMERICAN MARKET FOR CERAMIC CVD AEROSPACE COATINGS,
THROUGH 2020 ($ MILLIONS) 124
MARKET SHARE OF COMPANIES 124
TABLE 62 NORTH AMERICAN MARKET SHARE FOR CERAMIC CVD COATING SERVICE
PROVIDERS, 2014 (%) 125
CHAPTER 8 OTHER COATING TECHNIQUES 127
SPRAYING, BRUSH PAINTING AND DIPPING 127
SPRAYING 127
Metallic Ceramic Coating 128
Advantages of Metallic Ceramic Coating 128
Ceramic Coating 129
Why Ceramic Coatings for Automotive Finishing Needs? 129
Thermal Barrier Coating 129
Dry-Film Coating 130
TABLE 63 TEMPERATURE DROP USING COATED HEADERS IN AUTO ENGINES (°F) 130
PAINTING WITH A BRUSH 130
DIPPING 131
REPCOAT PROCESS 131
COATING UTILITIES 131
High-Temperature and Corrosion-Resistant Coatings 131
High-Temperature Insulative Coatings 132
ELECTRODEPOSITION 133
CEMENTATION 133
PACK CEMENTATION 134
Fluidized-Bed Cementation Process 134
Vapor-Stream Cementation 135
SOL-GEL PROCESSING 135
TABLE 64 APPLICATIONS OF SOL GEL FILMS AND COATINGS 135
DATEC PROCESS 136
USING LASERS FOR COATING 137
PULSED LASER DEPOSITION (PLD) 137
LASER-ASSISTED ATMOSPHERIC PLASMA SPRAYING 138
QQC PROCESS 139
ION-BEAM-ASSISTED DEPOSITION (IBAD) 139
ION BEAM SURFACE TREATMENT (IBEST) 139
ION-BEAM-ENHANCED DEPOSITION (IBED) 141
MICRODISCHARGE DEPOSITION 141
MICROPLASMIC COATING 142
MOLECULAR BEAM EPITAXY 143
AEROSOL DEPOSITION 143
INDUSTRY STRUCTURE 143
NORTH AMERICAN COMPANIES 143
TABLE 65 NORTH AMERICAN COMPANIES PROVIDING CERAMIC COATING SERVICES
USING SPRAYING, DIPPING, SOL GEL, LASER AND IONIC BEAM TECHNIQUES 144
NORTH AMERICAN MARKET 146
SPRAYING/BRUSH PAINTING/DIPPING 146
TABLE 66 NORTH AMERICAN MARKET FOR OTHER TYPES OF COATING SERVICE BY
APPLICATION, THROUGH 2020 ($ MILLIONS) 147
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 (%)
147
MARKET SHARE OF COMPANIES 148
CHAPTER 9 COMPANY PROFILES 150
PROFILES OF NORTH AMERICAN COMPANIES INVOLVED IN CERAMIC COATINGS
AS EQUIPMENT MANUFACTURERS, SUPPLIERS OF CONSUMABLES, COATING
SERVICE PROVIDERS AND USERS
150
AandA COATINGS INC. 150
ACCUWRIGHT INDUSTRIES INC. 150
ADVANCED CUTTING TOOLS INC. 150
AERO TURBINE INC. 151
AESTHETIC FINISHERS INC. 151
AIR PRODUCTS and CHEMICALS INC. 151
ALPHA TECH COATINGS INC. 152
AMERICAN ROLLER CO. 152
APPLIED MATERIALS 153
APS MATERIALS 154
AREMCO PRODUCTS INC. 154
ASB INDUSTRIES INC. 155
ADVANCED CERAMIC COATING INC. 155
CERAM-KOTE COATINGS INC. 156
CETEK LIMITED 157
CHEMAT TECHNOLOGY INC. 158
CHROMALLOY GAS TURBINE LLC 158
CHROMALLOY NEW YORK 158
CINCINNATI THERMAL SPRAY 159
COTRONICS CORP. 160
CURTISS-WRIGHT SURFACE TECHNOLOGIES 160
CVD EQUIPMENT CORP. 160
DATEC COATING CORP. 161
DENTON VACUUM 161
ELLISON SURFACE TECHNOLOGIES 162
ENVIRONMENTAL ABRASIVES 163
EUTECTIC CORP. 163
EXLINE INC. 163
FFWD CONNECTION 164
FLAME SPRAY COATING CO. INC. 164
GENERAL ELECTRIC CO. 165
GENERAL MAGNAPLATE CORP. 165
GRENCO ENERGY SERVICES 165
HAYDEN CORP. 166
HEANY INDUSTRIES INC. 166
HFW INDUSTRIES INC. 166
HITEMCO 167
HONEYWELL AEROSPACE 167
HOWMET CASTING SPECIAL PRODUCTS 167
HOWMET CASTINGS THERMATECH COATINGS 168
HOWMET TURBINE COMPONENTS COATINGS 168
INDUSTRIAL GRINDING 169
INDUSTRIAL MACHINE and MFG., LTD. 169
INFRAMAT CORP. 169
INGERSOLL CUTTING TOOL COMPANY 170
IONBOND INC. 170
JET-HOT COATINGS 171
KENNAMETAL INC. 171
KENNAMETAL STELLITE COATINGS 172
MER CORP. 172
NANOPHASE TECHNOLOGIES INC. 173
NGIMAT CO. 173
NORTHWEST METTECH CORP. 174
OERLIKON BALZERS COATING USA INC. 175
OERLIKON METCO (U.S.) INC. 175
PETERS PERFORMANCE CERAMIC COATING 176
PLASMA COATINGS INC. 176
PLASMA TECHNOLOGY INC. 177
PRATT and WHITNEY 177
PRAXAIR SURFACE TECHNOLOGIES INC. 177
PRAXAIR SURFACE TECHNOLOGIES/TAFA INC. 178
PRECISION COATINGS INC. 178
PRIEST ELECTRIC 178
PROFESSIONAL CRYOGENIC METALLURGY and COATINGS LLC (PCMC) 179
PROSTRIP PROFESSIONAL METAL REFINISHING INC. 179
PROGRESSIVE SURFACE INC. 179
RAM PRO-LINE 180
SAINT GOBAIN CERAMIC MATERIALS 180
SANDVIK INC. 180
SECO TOOLS INC. 181
SOLAR ATMOSPHERES INC. 181
SPECIALIZED CERAMIC AND POWDER COATINGS 182
SPIRE CORP. 182
ST. LOUIS METALLIZING CO. 183
STARFIRE SYSTEMS INC. 183
PERFORMANCE ROD and CUSTOM 184
SYLCO INC. 184
SWAIN TECHNOLOGY INC. 185
TECH LINE COATINGS INC. 185
TECHNETICS GROUP 185
THIN AIR POWERSPORTS 186
ULTRAMET 186
ULVAC TECHNOLOGIES INC. 186
UTC AEROSPACE SYSTEMS 187
WHITE ENGINEERING SURFACES CORP. 187

LIST OF TABLES

SUMMARY TABLE NORTH AMERICAN MARKET FOR HIGH-PERFORMANCE CERAMIC
COATINGS BY TYPE, THROUGH 2020 ($ MILLIONS) 8
TABLE 1 NORTH AMERICAN MARKET FOR HIGH-PERFORMANCE CERAMIC COATINGS,
BY APPLICATION SEGMENT, THROUGH 2020 ($ MILLIONS) 12
TABLE 2 HIGH-PERFORMANCE CERAMIC COATING MATERIALS AND GENERAL
APPLICATIONS 15
TABLE 3 REPRESENTATIVE FLAME AND PLASMA-SPRAYED MATERIALS, MELTING OR
SOFTENING TEMPERATURE AND USES 16
TABLE 4 PLASMA-SPRAYED CERAMIC COATING PROPERTIES 17
TABLE 5 LEADING APPLICATIONS OF DEPOSITION BY INDUSTRY 20
TABLE 6 TYPICAL COATINGS AND APPLICATIONS 21
TABLE 7 CERAMIC MATERIALS USED IN THE POWDER FLAME PROCESS 26
TABLE 8 PROPERTIES OF HVOF CARBIDE COATINGS 35
TABLE 9 COMPARISON OF THERMAL SPRAY PROCESSES 38
TABLE 10 DETONATION GUN APPLICATIONS IN GAS TURBINE ENGINES 41
TABLE 11 THERMAL SPRAY COATINGS FOR FRPS 51
TABLE 12 RECENT DEVELOPMENTS IN THERMAL SPRAY COATINGS 52
TABLE 13 LEADING U.S. COMPANIES PROVIDING THERMAL SPRAY COATING
SERVICES FOR OEM PARTS 54
TABLE 14 NORTH AMERICAN CUSTOM/JOB SHOPS PROVIDING THERMAL SPRAY
COATING SERVICES 55
TABLE 15 LEADING U.S. COMPANIES PROVIDING THERMAL SPRAY COATING
CONSUMABLES 56
TABLE 16 U.S. COMPANIES SUPPLYING CONSUMABLES FOR NANOCERAMIC
COATINGS 56
TABLE 17 U.S. MANUFACTURERS OF PLASMA SPRAY EQUIPMENT 56
TABLE 18 ACQUISITIONS, MERGERS AND OTHER BUSINESS RELATIONS IN THE
THERMAL SPRAY INDUSTRY, SINCE 1990 57
TABLE 19 NORTH AMERICAN MARKET FOR THERMAL SPRAY CERAMIC COATING OF
AIRCRAFT GAS TURBINE PARTS BY ENGINE TYPE, THROUGH 2020 ($ MILLIONS) 58
TABLE 20 NORTH AMERICAN SHIPMENTS OF TURBOFAN, TURBOPROP AND
TURBOSHAFT ENGINES, THROUGH 2020 (UNITS) 59
TABLE 21 COST OF AIRCRAFT ENGINE COATING SERVICES, THROUGH 2020 ($
MILLIONS) 60
TABLE 22 NORTH AMERICAN MARKET FOR AIRCRAFT GAS TURBINE ENGINE
OVERHAUL, THROUGH 2020 ($ MILLIONS/UNITS/$) 61
TABLE 23 NORTH AMERICAN MARKET FOR THERMAL SPRAY CERAMIC COATING OF
LARGE LAND-BASED TURBINE PARTS, THROUGH 2020 ($ MILLIONS) 61
TABLE 24 COST OF NEW LARGE LAND-BASED TURBINE COATING SERVICES,
THROUGH 2020 ($ MILLIONS) 62
TABLE 25 COST OF LARGE LAND-BASED TURBINE REFURBISHMENT COATING
SERVICES, THROUGH 2020 ($ MILLIONS) 62
TABLE 26 NORTH AMERICAN MARKET FOR THERMAL SPRAY CERAMIC COATING OF
WEAR-RESISTANT PARTS AND INDUSTRIAL APPLICATIONS, THROUGH 2020 ($
MILLIONS)
63
TABLE 27 NORTH AMERICAN MARKET FOR THERMAL SPRAY CERAMIC COATINGS IN
AUTOMOTIVE AND DIESEL ENGINES, THROUGH 2020 ($ MILLIONS) 65
TABLE 28 NORTH AMERICAN MARKET FOR THERMAL SPRAY CERAMIC COATINGS
FOR MEDICAL APPLICATIONS, THROUGH 2020 ($ MILLIONS) 66
TABLE 29 NORTH AMERICAN MARKET FOR CERAMIC THERMAL SPRAY COATING BY
SEGMENT, THROUGH 2020 ($ MILLIONS) 67
TABLE 30 NORTH AMERICAN MARKET SHARE FOR THERMAL SPRAY COATING
SERVICE PROVIDERS, 2014 (%) 69
TABLE 31 REPRESENTATIVE FILMS DEPOSITED BY PVD 72
TABLE 32 REPRESENTATIVE PVD SURFACE COATINGS FOR ABRASION- AND
CORROSION-RESISTANT APPLICATIONS 73
TABLE 33 TYPES OF PHYSICAL VAPOR DEPOSITION PROCESSES 75
TABLE 34 BASIC SPUTTERING SOURCES AND PROCESSES 79
TABLE 35 COMPARISON OF MAGNETRON SPUTTERING METHODS FOR DEPOSITING
SIO2 81
TABLE 36 CERAMIC PVD APPLICATIONS 86
TABLE 37 PROPERTIES OF UNCOATED AND TIN-COATED HIGH SPEED STEEL (HSS) 88
TABLE 38 PROPERTIES AND APPLICATION OF VARIOUS BALZERS BALINIT THIN-FILM
WEAR-RESISTANT COATINGS 89
TABLE 39 RECENT DEVELOPMENTS IN PVD 92
TABLE 40 LEADING NORTH AMERICAN COMPANIES MANUFACTURING PVD SYSTEMS
AND/OR PROVIDING SERVICES 94
TABLE 41 NORTH AMERICAN MARKET FOR HIGH-PERFORMANCE CERAMIC PVD
COATING BY SEGMENT, THROUGH 2020 ($ MILLIONS) 95
TABLE 42 NORTH AMERICAN MARKET FOR CERAMIC PVD TOOL COATINGS,
THROUGH 2020 ($ MILLIONS) 96
TABLE 43 NORTH AMERICAN MARKET FOR CERAMIC COATINGS FOR AUTOMOTIVE,
AEROSPACE AND WEAR-RESISTANT APPLICATIONS, THROUGH 2020 ($ MILLIONS) 97
TABLE 44 NORTH AMERICAN MARKET FOR CERAMIC PVD MEDICAL DEVICE
COATINGS, THROUGH 2020 ($ MILLIONS) 98
TABLE 45 NORTH AMERICAN MARKET SHARE FOR CERAMIC PVD COATING BY
SERVICE PROVIDERS, 2014 (%) 98
TABLE 46 CERAMICS DEPOSITED BY CVD 101
TABLE 47 TYPICAL CERAMIC CVD COATINGS, PROCESS GASES AND DEPOSITION
TEMPERATURES 103
TABLE 48 CCVD MATERIALS, SUBSTRATES AND APPLICATIONS 109
TABLE 49 KEY TECHNICAL ADVANTAGES OF THE CVD PROCESS 109
TABLE 50 KEY TECHNICAL DISADVANTAGES OF THE CVD PROCESS 110
TABLE 51 REPRESENTATIVE CVD CERAMIC COATINGS 110
TABLE 52 OVERVIEW OF CUTTING TOOL CVD APPLICATIONS 113
TABLE 53 RECENT DEVELOPMENTS IN CERAMIC CVD COATING 115
TABLE 54 LEADING GLOBAL MANUFACTURERS OF CVD EQUIPMENT 116
TABLE 55 LEADING GLOBAL CVD SERVICE PROVIDERS 117
TABLE 56 NORTH AMERICAN MARKET FOR CERAMIC CVD COATING SERVICE BY
APPLICATION, THROUGH 2020 ($ MILLIONS) 118
TABLE 57 NORTH AMERICAN MARKET FOR CERAMIC CVD TOOL INSERT COATINGS,
THROUGH 2020 ($ MILLIONS) 120
TABLE 58 NORTH AMERICAN MARKET FOR CERAMIC CVD WEAR-RESISTANT AND
OTHER INDUSTRIAL COATING APPLICATIONS, THROUGH 2020 ($ MILLIONS) 121
TABLE 59 NORTH AMERICAN MARKET FOR CERAMIC CVD AUTOMOTIVE COMPONENT
COATINGS, THROUGH 2020 ($ MILLIONS) 122
TABLE 60 NORTH AMERICAN MARKET FOR CERAMIC CVD AEROSPACE COATINGS,
THROUGH 2020 ($ MILLIONS) 123
TABLE 60 NORTH AMERICAN MARKET FOR CERAMIC CVD AEROSPACE COATINGS,
THROUGH 2020 ($ MILLIONS) 124
TABLE 62 NORTH AMERICAN MARKET SHARE FOR CERAMIC CVD COATING SERVICE
PROVIDERS, 2014 (%) 125
TABLE 63 TEMPERATURE DROP USING COATED HEADERS IN AUTO ENGINES (°F) 130
TABLE 64 APPLICATIONS OF SOL GEL FILMS AND COATINGS 135
TABLE 65 NORTH AMERICAN COMPANIES PROVIDING CERAMIC COATING SERVICES
USING SPRAYING, DIPPING, SOL GEL, LASER AND IONIC BEAM TECHNIQUES 144
TABLE 66 NORTH AMERICAN MARKET FOR OTHER TYPES OF COATING SERVICE BY
APPLICATION, THROUGH 2020 ($ MILLIONS) 147
AVM015H - High-Performance Ceramic Coatings: Markets and Technologies

List of Figures

SUMMARY FIGURE NORTH AMERICAN MARKET SHARE FOR HIGH-PERFORMANCE
CERAMIC COATING TECHNOLOGIES BY TYPE, 2014 TO 2020 (%) 8
FIGURE 1 NORTH AMERICAN MARKET SHARE FOR HIGH-PERFORMANCE CERAMIC
COATING BY APPLICATION SEGMENTS, 2014 TO 2020 (%) 12
FIGURE 2 PLASMA SPRAY COATING TECHNIQUE 29
FIGURE 3 SCHEMATIC OF HVOF 34
FIGURE 4 NORTH AMERICAN MARKET SHARE FOR CERAMIC THERMAL SPRAY
COATING SERVICE BY SEGMENTS, 2014 TO 2020 (%) 67
FIGURE 5 COMPARISON OF THE TRS OF UNCOATED AND COATED CARBIDE* (TRS
MPA) 88
FIGURE 6 NORTH AMERICAN MARKET SHARE FOR CERAMIC THERMAL SPRAY
COATING SERVICE BY SEGMENT, 2014 TO 2020 (%) 95
FIGURE 7 SUMMARY OF CARBIDE METALCUTTING GRADE DEVELOPMENT 112
FIGURE 8 NORTH AMERICAN MARKET SHARE FOR CERAMIC CVD COATING SERVICE
BY APPLICATION, 2014 TO 2020 (%) 119
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 (%)
147

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