High-Performance Ceramic Coatings: Markets and Technologies

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High-Performance Ceramic Coatings: Markets and Technologies

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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 2012, 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 edition's 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 or to 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 and at the same time increased 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 2018. 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 kinds 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.
• 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 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. All market table values are in 2012 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 feels, therefore, 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 and 2012. Both primary and secondary research methodologies were used in preparing 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 utilizing 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.

AUTHOR'S CREDENTIALS

This report is an update of an earlier report prepared by Dr. Thomas Abraham. Dr. Abraham was formerly Vice President and Director of the Advanced Materials Group of BCC Research. Dr. Abraham has extensive experience in the field of advanced materials, including advanced ceramics, synthetic diamonds and diamond films, magnetic materials, high-performance coatings and superconductors.
The analyst responsible for updating the report is Andrew McWilliams, a partner in the Boston-based international technology and marketing consulting firm, 43rd Parallel LLC. Mr. McWilliams is the author or co-author of numerous other BCC Research studies including a number in related fields such as AVM025G Diamond, Diamond-Like and CBN Films and Coating Products; NAN015F Advanced Ceramics and Nanoceramic Powders; NAN021E Global Markets for Nanocomposites, Nanoparticles, Nanoclays and Nanotubes; NAN040A Nanomaterials Markets by Type; and AVM008B Synthetic Gems and Minerals.

REPORT HIGHLIGHTS

The North American market for high-performance ceramic coatings was worth more than $1.1 billion in 2012. This figure is expected to increase to $1.2 billion in 2013 and nearly $1.7 billion by 2018, with a projected five-year compound annual growth rate (CAGR) of 6.6%.

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.
• 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.
TABLE OF CONTENTS

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
AUTHOR'S CREDENTIALS 5
RELATED BCC RESEARCH REPORTS 5
BCC RESEARCH ONLINE SERVICES 5
DISCLAIMER 6

CHAPTER 2 EXECUTIVE SUMMARY 8

SUMMARY TABLE NORTH AMERICAN MARKET FOR HIGH-PERFORMANCE CERAMIC
COATINGS BY TYPE OF COATING TECHNOLOGY, THROUGH 2018 ($ MILLIONS) 8
SUMMARY FIGURE F:\BCCRESEARCH\NEW WEBSITE
CONTENT\AVM\2014\AVM015G\IMAGES (% TOTAL MARKET) 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 2018 ($ MILLIONS) 12
FIGURE 1 SHARE OF NORTH AMERICAN HIGH-PERFORMANCE CERAMIC COATING
SERVICE MARKET SEGMENTS, 2012-2018 (%) 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 27
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 33
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 36
DETONATION THERMAL SPRAY PROCESS 37
PROCESS COMPARISONS 37
TABLE 9 COMPARISON OF THERMAL SPRAY PROCESSES 38
APPLICATIONS 38
AIRCRAFT ENGINES AND AEROSPACE 39
Gas Turbine Engines 39
TABLE 10 DETONATION GUN APPLICATIONS IN GAS TURBINE ENGINES 41
LAND-BASED GAS TURBINES 44
AUTOMOTIVE COMPONENTS 44
Engine Components 45
Exhaust Manifolds 47
DIESEL ENGINES 47
HEAT EXCHANGERS AND BOILERS 48
HIGH-TEMPERATURE CORROSION-RESISTANT APPLICATIONS 48
WEAR-RESISTANT AND INDUSTRIAL APPLICATIONS 49
MEDICAL 50
OTHER EMERGING APPLICATIONS AND COMPOSITIONS 50
TABLE 11 THERMAL SPRAY COATINGS FOR FRPS 50
RECENT DEVELOPMENTS 51
TABLE 12 RECENT DEVELOPMENTS IN THERMAL SPRAY COATINGS 51
TECHNOLOGIES 52
Method of Making a Barbed Surface for Receiving a Thermal Spray
Coating and the Surface Produced 53
MATERIALS 54
Amorphous-Nanocrystalline-Microcrystalline Coatings and Methods of
Production 54
Thermal Spray Powder Method for Forming Thermal Spray Coating
and Plasma Resistant Members 54
APPLICATIONS 55
Method and Device for Producing a Dispersion-Hardened Object
Containing Carbide Nanoparticles 55
Acoustic Wave Device and Manufacturing Method 55
MISCELLANEOUS DEVELOPMENTS 55
System and Method for Measuring Coating Thickness 55
INDUSTRY STRUCTURE 56
NORTH AMERICAN COMPANIES 56
TABLE 13 LEADING U.S. COMPANIES PROVIDING THERMAL SPRAY COATING
SERVICES FOR OEM PARTS 57
TABLE 14 NORTH AMERICAN CUSTOM/JOB SHOPS PROVIDING THERMAL SPRAY
COATING SERVICES 57
TABLE 15 LEADING U.S. COMPANIES PROVIDING THERMAL SPRAY COATING
CONSUMABLES 58
TABLE 16 U.S. COMPANIES SUPPLYING CONSUMABLES FOR NANOCERAMIC
COATINGS 58
TABLE 17 U.S. MANUFACTURERS OF PLASMA SPRAY EQUIPMENT 59
ACQUISITIONS, MERGERS AND OTHER BUSINESS RELATIONSHIPS 59
TABLE 18 ACQUISITIONS, MERGERS AND OTHER BUSINESS RELATIONS IN THE
THERMAL SPRAY INDUSTRY SINCE 1990 59
NORTH AMERICAN MARKETS 60
TURBINE ENGINES OEM AND OVERHAUL 60
Aircraft Engines 60
TABLE 19 TOTAL NORTH AMERICAN EXPENDITURES ON THERMAL SPRAY CERAMIC
COATING OF AIRCRAFT GAS TURBINE PARTS, THROUGH 2018 ($ MILLIONS) 60
TABLE 20 NORTH AMERICAN SHIPMENTS OF TURBOFAN, TURBOPROP AND
TURBOSHAFT ENGINES, THROUGH 2018 (NUMBER OF ENGINES) 61
TABLE 21 COST OF AIRCRAFT ENGINE COATING SERVICES, THROUGH 2018 ($
MILLIONS) 62
TABLE 22 NORTH AMERICAN AIRCRAFT GAS TURBINE ENGINE OVERHAUL MARKET,
THROUGH 2018 ($ MILLIONS) 63
Land-Based Turbines 63
TABLE 23 TOTAL NORTH AMERICAN EXPENDITURES ON THERMAL SPRAY CERAMIC
COATING OF LARGE LAND-BASED TURBINE PARTS, THROUGH 2018 ($ MILLIONS) 63
TABLE 24 COST OF NEW LARGE LAND-BASED TURBINE COATING SERVICES,
2012–2018 ($ MILLIONS) 64
TABLE 25 COST OF LARGE LAND-BASED TURBINE REFURBISHMENT COATING
SERVICES, THROUGH 2018 ($ MILLIONS) 65
WEAR-RESISTANT PARTS AND INDUSTRIAL APPLICATIONS 65
TABLE 26 TOTAL NORTH AMERICAN EXPENDITURES ON THERMAL SPRAY CERAMIC
COATING OF WEAR-RESISTANT PARTS AND INDUSTRIAL APPLICATIONS, THROUGH
2018` ($ MILLIONS)
66
AUTOMOTIVE AND DIESEL ENGINES 66
TABLE 27 TOTAL NORTH AMERICAN EXPENDITURES ON THERMAL SPRAY CERAMIC
COATINGS IN AUTOMOTIVE AND DIESEL ENGINES, THROUGH 2018 ($ MILLIONS) 67
MEDICAL 67
TABLE 28 TOTAL NORTH AMERICAN EXPENDITURES ON THERMAL SPRAY CERAMIC
COATINGS FOR MEDICAL APPLICATIONS, THROUGH 2018 ($ MILLIONS) 68
HEAT EXCHANGERS AND HIGH TEMPERATURE 68
OTHER APPLICATIONS 68
MARKET AND MARKET SHARES 68
TABLE 29 NORTH AMERICAN CERAMIC THERMAL SPRAY COATING MARKET,
THROUGH 2018 ($ MILLIONS) 68
FIGURE 4 SHARE OF NORTH AMERICAN CERAMIC THERMAL SPRAY COATING
SERVICE MARKET SUBSEGMENTS, 2012-2018 (% TOTAL THERMAL SPRAY MARKET) 70
MARKET SHARE OF COMPANIES 70
TABLE 30 MARKET SHARE OF THERMAL SPRAY COATING SERVICE PROVIDERS,
2012 (%) 71

CHAPTER 6 PHYSICAL VAPOR DEPOSITION (PVD) 73

BASIC PRINCIPLES 73
PVD MATERIALS 74
TABLE 31 REPRESENTATIVE FILMS DEPOSITED BY PVD 74
TABLE 32 REPRESENTATIVE PVD SURFACE COATINGS FOR ABRASION- AND
CORROSION-RESISTANT APPLICATIONS 75
TITANIUM NITRIDE COATING (TIN) 75
TITANIUM CARBO NITRIDE COATING (TICN) 75
TITANIUM ALUMINUM NITRIDE COATING (TIALN) 75
TITANIUM DIBORIDE COATING (TIB2) 76
TIALN-X 76
CHROMIUM NITRIDE COATING (CRN) 76
SUPER R COATING 76
ZIRCONIUM NITRIDE COATING (ZRN) 76
PVD TECHNOLOGIES 76
TABLE 33 TYPES OF PHYSICAL VAPOR DEPOSITION PROCESSES 77
PVD BY EVAPORATION 77
Evaporation Sources 78
Evaporation Deposition Processes 78
Thermal Evaporation 79
Electron-Beam Evaporation 79
PVD ARC PROCESS 80
PVD BY SPUTTERING 80
Sputtering Sources and Processes 81
TABLE 34 BASIC SPUTTERING SOURCES AND PROCESSES 81
Direct Current (DC) Diode Sputtering 81
Triode Sputtering 82
Radio Frequency (RF) Sputtering 82
Magnetron Sputtering 82
TABLE 35 COMPARISON OF MAGNETRON SPUTTERING METHODS FOR DEPOSITING
SIO2 83
Linear Magnetron Sputtering 83
Unbalanced Magnetron Sputtering 83
Ion Beam Sputtering 84
Sputter Ion Plating (SIP) Process 84
Co-sputtering 85
Reactive Sputtering 85
COMPARISON OF EVAPORATION AND SPUTTERING 86
MULTICHAMBER SYSTEM 87
PVD ADVANTAGES AND LIMITATIONS 87
PVD APPLICATIONS 88
TABLE 36 CERAMIC PVD APPLICATIONS 88
TOOLS 89
TABLE 37 PROPERTIES OF UNCOATED AND TIN-COATED HIGH SPEED STEEL (HSS) 90
FIGURE 5 COMPARISON OF THE TRS OF UNCOATED AND COATED CARBIDE * (TRS
MPA) 90
TABLE 38 PROPERTIES AND APPLICATION OF VARIOUS BALZERS BALINIT THIN-FILM
WEAR-RESISTANT COATINGS 91
TURBINE VANES AND BLADES 93
OTHER AEROSPACE APPLICATIONS 93
RECENT DEVELOPMENTS 94
TABLE 39 RECENT DEVELOPMENTS IN PVD 94
TECHNOLOGIES 94
Physical Vapor Deposition with Phase Shift 94
Method for Simultaneously Coating a Plurality of Workpieces 94
PVD Target with End of Service Life Detection Capability 95
APPLICATIONS 95
Thin Film Batteries and Methods for Manufacturing Same 95
INDUSTRY STRUCTURE 95
NORTH AMERICAN COMPANIES 96
TABLE 40 LEADING NORTH AMERICAN COMPANIES MANUFACTURING PVD
SYSTEMS AND/OR PROVIDING SERVICES 96
NORTH AMERICAN MARKETS 97
TABLE 41 NORTH AMERICAN HIGH-PERFORMANCE CERAMIC PVD COATING
MARKET, THROUGH 2018 ($ MILLIONS) 97
FIGURE 6 SHARE OF NORTH AMERICAN CERAMIC THERMAL SPRAY COATING
SERVICE MARKET SUBSEGMENTS, 2012-2018 (% OF TOTAL THERMAL SPRAY
MARKET)
98
TOOLS 98
TABLE 42 NORTH AMERICAN MARKET FOR CERAMIC PVD TOOL COATINGS,
THROUGH 2018 ($ MILLIONS) 99
INDUSTRIAL SERVICES 99
TABLE 43 NORTH AMERICAN MARKET FOR CERAMIC COATINGS FOR AUTOMOTIVE,
AEROSPACE AND WEAR-RESISTANT APPLICATIONS, THROUGH 2018 ($ MILLIONS) 99
MEDICAL 99
TABLE 44 NORTH AMERICAN MARKET FOR CERAMIC PVD MEDICAL DEVICE
COATINGS, THROUGH 2018 ($ MILLIONS) 100
MARKET SHARE OF COMPANIES 100
TABLE 45 NORTH AMERICAN MARKET FOR CERAMIC PVD MEDICAL DEVICE
COATINGS, THROUGH 2018 ($ MILLIONS) 101

CHAPTER 7 CHEMICAL VAPOR DEPOSITION (CVD) 103

BASIC PRINCIPLE 103
CVD MATERIALS 104
TABLE 46 CERAMICS DEPOSITED BY CVD 104
CVD TECHNIQUES 106
TABLE 47 TYPICAL CERAMIC CVD COATINGS, PROCESS GASES AND DEPOSITION
TEMPERATURES 106
BASIC THERMAL CVD PROCESS 106
Metallo-Organic CVD (MOCVD) 107
Atmospheric Pressure CVD 107
Low-Pressure CVD 107
PLASMA-ASSISTED CVD 108
DC Plasma Method 108
RF Induction Plasma 109
Microwave Plasma Torch 109
Cathodic-Arc Plasma Deposition 109
High-Energy Intensified Plasma-Assisted Processing (HEIPAP) 110
COMBUSTION CHEMICAL VAPOR DEPOSITON (CCVD) 111
TABLE 48 CCVD MATERIALS, SUBSTRATES AND APLICAITONS 112
ADVANTAGES AND DISADVANTAGES OF CVD 112
TABLE 49 KEY TECHNICAL ADVANTAGES OF THE CVD PROCESS 112
TABLE 50 KEY TECHNICAL DISADVANTAGES OF THE CVD PROCESS 113
CVD APPLICATIONS 113
TABLE 51 REPRESENTATIVE CVD CERAMIC COATINGS 113
CUTTING TOOLS 114
FIGURE 7 SUMMARY OF CARBIDE METALCUTTING GRADE DEVELOPMENT 115
TABLE 52 OVERVIEW OF CURRENT/EMERGING CUTTING TOOL CVD APPLICATIONS 116
INDUSTRIAL APPLICATIONS 116
AEROSPACE 117
HIGH-TEMPERATURE APPLICATIONS 117
FOULING-RESISTANT CERAMIC MEMBRANES 118
NEW DEVELOPMENTS 118
TABLE 53 RECENT DEVELOPMENTS IN CERAMIC CVD COATING 118
CVD COATED POLYCRYSTALLINE C-BN CUTTING TOOL 118
INDUSTRY STRUCTURE 118
LEADING CVD SYSTEMS MANUFACTURERS 119
TABLE 54 LEADING WORLDWIDE MANUFACTURERS OF CVD EQUIPMENT 119
LEADING CVD SERVICE PROVIDERS 120
TABLE 55 LEADING WORLDWIDE CVD SERVICE PROVIDERS 120
NORTH AMERICAN MARKET 121
TABLE 56 NORTH AMERICAN CERAMIC CVD COATING SERVICE MARKETS BY
APPLICATION, THROUGH 2018 ($ MILLIONS) 121
FIGURE 8 SHARE OF NORTH AMERICAN CERAMIC CVD COATING SERVICE MARKET
SEGMENTS, 2012-2018 (% OF TOTAL CVD COATING MARKET) 122
TOOLS 123
TABLE 57 NORTH AMERICAN MARKET FOR CERAMIC CVD TOOL INSERT COATINGS,
THROUGH 2018 ($ MILLIONS) 123
WEAR-RESISTANT AND INDUSTRIAL APPLICATIONS 123
TABLE 58 NORTH AMERICAN MARKET FOR CERAMIC CVD WEAR-RESISTANT AND
OTHER INDUSTRIALCOATING APPLICATIONS, THROUGH 2018 ($ MILLIONS) 124
AUTOMOTIVE 124
AIRCRAFT AND AEROSPACE 125
TABLE 60 NORTH AMERICAN MARKET FOR CERAMIC CVD AEROSPACE COATINGS,
THROUGH 2018 ($ MILLIONS) 126
MEDICAL 126
MARKET SHARE OF COMPANIES 126
TABLE 62 MARKET SHARE OF CERAMIC CVD COATING SERVICE PROVIDERS, 2010 126

CHAPTER 8 OTHER COATING TECHNIQUES 129

SPRAYING, BRUSH PAINTING AND DIPPING 129
SPRAYING 129
Metallic Ceramic Coating 129
Ceramic Coating 130
Thermal Barrier Coating 130
Dry-Film Coating 131
TABLE 63 TEMPERATURE DROP USING COATED HEADERS IN AUTO ENGINES (°F) 131
PAINTING WITH A BRUSH 132
DIPPING 132
REPCOAT PROCESS 133
COATING UTILITIES 133
High-Temperature and Corrosion-Resistant Coatings 133
High-Temperature Insulative Coatings 134
ELECTRODEPOSITION 135
CEMENTATION 135
PACK CEMENTATION 135
Fluidized-Bed Cementation Process 136
Vapor-Stream Cementation 136
SOL GEL PROCESSING 137
TABLE 64 APPLICATIONS OF SOL GEL FILMS AND COATINGS 137
DATEC PROCESS 138
USING LASERS FOR COATING 139
PULSED LASER DEPOSITION (PLD) 139
LASER-ASSISTED ATMOSPHERIC PLASMA SPRAYING 140
QQC PROCESS 140
ION-BEAM-ASSISTED DEPOSITION (IBAD) 141
ION BEAM SURFACE TREATMENT (IBEST) 141
ION-BEAM-ENHANCED DEPOSITION (IBED) 142
MICRODISCHARGE DEPOSITION 143
MICROPLASMIC COATING 143
INDUSTRY STRUCTURE 145
NORTH AMERICAN COMPANIES 145
TABLE 65 NORTH AMERICAN COMPANIES PROVIDING CERAMIC COATING SERVICES
USING SPRAYING, DIPPING, SOL GEL, LASER AND IONIC BEAM TECHNIQUES 145
NORTH AMERICAN MARKET 147
SPRAYING/BRUSH PAINTING/DIPPING 147
TABLE 66 NORTH AMERICAN MARKET FOR OTHER TYPES OF COATING SERVICE BY
APPLICATION, THROUGH 2018 ($ MILLIONS) 148
FIGURE 9 SHARE OF NORTH AMERICAN CERAMIC COATINGS MARKET USING
SPRAYING/ DIPPING, SOL GEL, MICRO OXIDATION AND LASER-ASSISTED
TECHNIQUES BY APPLICATION, 2012-2018 (%)
149
MARKET SHARE OF COMPANIES 150

CHAPTER 9 COMPANY PROFILES 152

PROFILES OF NORTH AMERICAN COMPANIES INVOLVED IN CERAMIC COATINGS
AS EQUIPMENT MANUFACTURERS, SUPPLIERS OF CONSUMABLES, COATING
SERVICE PROVIDERS AND USERS
152
A&A COMPANY, INC. 152
ACCUWRIGHT INDUSTRIES, INC. 152
ADVANCED CUTTING TOOLS, INC. 152
AERO TURBINE, INC. 153
AESTHETIC FINISHERS, INC. 153
AIR PRODUCTS & CHEMICALS, INC. 153
ALPHA TECH COATINGS (ATC), INC. 154
AMERICAN ROLLER CO. 154
APPLIED MATERIALS 155
APS MATERIALS 155
AREMCO PRODUCTS INC. 156
ASB INDUSTRIES 156
CERAMIC COATING, INC. 157
CETEK LIMITED 157
CHEMAT TECHNOLOGY, INC. 158
CHROMALLOY GAS TURBINE, LLC 158
CHROMALLOY NEW YORK 159
CINCINNATI THERMAL SPRAY 159
COTRONICS CORP. 160
CURTISS-WRIGHT SURFACE TECHNOLOGIES 160
CVD EQUIPMENT CORP. 161
DATEC COATING CORP. 161
DENTON VACUUM 162
ELLISON SURFACE TECHNOLOGIES 162
ENVIRONMENTAL ABRASIVES 163
EUTECTIC CORP. 163
EXLINE, INC. 164
FREECOM, INC. 164
F.W. GARTNER THERMAL SPRAYING CO. 166
FFWD CONNECTION 166
FLAME SPRAY COATING CO., INC. 166
GENERAL ELECTRIC CO. 167
GENERAL MAGNAPLATE CORP. 167
GRENCO ENERGY SERVICES 168
GSEM, INC. 168
HAYDEN CORP. 168
HEANY INDUSTRIES, INC. 169
HFW INDUSTRIES, INC. 169
HITEMCO 169
HONEYWELL AEROSPACE 170
HOWMET CASTING SPECIAL PRODUCTS 170
HOWMET CASTINGS THERMATECH COATINGS 170
HOWMET TURBINE COMPONENTS COATINGS 171
INDUSTRIAL GRINDING 171
INDUSTRIAL MACHINE & MFG., LTD. 171
INFRAMAT CORP. 172
INGERSOLL CUTTING TOOL COMPANY 172
IONBOND, INC. 173
JET-HOT COATINGS 173
KENNAMETAL, INC. 174
KENNAMETAL STELLITE COATINGS 174
MER CORP. 175
MICROPLASMIC CORP. 175
NANOPHASE TECHNOLOGIES, INC. 176
NGIMAT CO. 176
NORTHWEST METTECH CORP. 177
OERLIKON SYSTEMS UNITED STATES 178
PETERS PERFORMANCE CERAMIC COATING 179
PLASMA COATINGS, INC. 179
PLASMA TECHNOLOGY, INC. 179
PRATT & WHITNEY 180
PRAXAIR SURFACE TECHNOLOGIES, INC. 180
PRAXAIR TAFA 180
PRECISION COATINGS, INC. 181
PRIEST ELECTRIC 181
PROFESSIONAL CRYOGENIC METALLURGY & COATINGS LLC (PCMC) 181
PROFESSIONAL METAL REFINISHING, INC. 182
PROGRESSIVE TECHNOLOGIES, INC. 182
RAM PRO LINE 182
SAINT GOBAIN CERAMIC MATERIALS 182
SANDVIK, INC. 183
SECO TOOLS, INC. 183
SOLAR ATMOSPHERES, INC. 184
SPECIALIZED CERAMIC AND POWDER COATINGS 184
SPIRE CORP. 184
ST. LOUIS METALIZING CO. 186
STARFIRE SYSTEMS, INC. 186
STEEL PLANT EQUIPMENT CORP 187
STREETROD STUFF, INC. 188
SULZER METCO (U.S.), INC. 188
SYLCO, INC. 188
SWAIN TECHNOLOGY, INC. 189
TECH LINE COATINGS, INC. 189
TECHNETICS CORP. 189
THIN AIR POWERSPORTS 190
TURBINE COMPONENTS SERVICES 190
ULTRAMET 190
ULVAC TECHNOLOGIES, INC. 191
WHITE ENGINEERING SURFACES CORP. 191



LIST OF TABLES

SUMMARY TABLE NORTH AMERICAN MARKET FOR HIGH-PERFORMANCE CERAMIC
COATINGS BY TYPE OF COATING TECHNOLOGY, THROUGH 2018 ($ MILLIONS) 8
TABLE 1 NORTH AMERICAN MARKET FOR HIGH-PERFORMANCE CERAMIC COATINGS,
BY APPLICATION SEGMENT, THROUGH 2018 ($ 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 50
TABLE 12 RECENT DEVELOPMENTS IN THERMAL SPRAY COATINGS 51
TABLE 13 LEADING U.S. COMPANIES PROVIDING THERMAL SPRAY COATING
SERVICES FOR OEM PARTS 57
TABLE 14 NORTH AMERICAN CUSTOM/JOB SHOPS PROVIDING THERMAL SPRAY
COATING SERVICES 57
TABLE 15 LEADING U.S. COMPANIES PROVIDING THERMAL SPRAY COATING
CONSUMABLES 58
TABLE 16 U.S. COMPANIES SUPPLYING CONSUMABLES FOR NANOCERAMIC
COATINGS 58
TABLE 17 U.S. MANUFACTURERS OF PLASMA SPRAY EQUIPMENT 59
TABLE 18 ACQUISITIONS, MERGERS AND OTHER BUSINESS RELATIONS IN THE
THERMAL SPRAY INDUSTRY SINCE 1990 59
TABLE 19 TOTAL NORTH AMERICAN EXPENDITURES ON THERMAL SPRAY CERAMIC
COATING OF AIRCRAFT GAS TURBINE PARTS, THROUGH 2018 ($ MILLIONS) 60
TABLE 20 NORTH AMERICAN SHIPMENTS OF TURBOFAN, TURBOPROP AND
TURBOSHAFT ENGINES, THROUGH 2018 (NUMBER OF ENGINES) 61
TABLE 21 COST OF AIRCRAFT ENGINE COATING SERVICES, THROUGH 2018 ($
MILLIONS) 62
TABLE 22 NORTH AMERICAN AIRCRAFT GAS TURBINE ENGINE OVERHAUL MARKET,
THROUGH 2018 ($ MILLIONS) 63
TABLE 23 TOTAL NORTH AMERICAN EXPENDITURES ON THERMAL SPRAY CERAMIC
COATING OF LARGE LAND-BASED TURBINE PARTS, THROUGH 2018 ($ MILLIONS) 63
TABLE 24 COST OF NEW LARGE LAND-BASED TURBINE COATING SERVICES,
2012–2018 ($ MILLIONS) 64
TABLE 25 COST OF LARGE LAND-BASED TURBINE REFURBISHMENT COATING
SERVICES, THROUGH 2018 ($ MILLIONS) 65
TABLE 26 TOTAL NORTH AMERICAN EXPENDITURES ON THERMAL SPRAY CERAMIC
COATING OF WEAR-RESISTANT PARTS AND INDUSTRIAL APPLICATIONS, THROUGH
2018` ($ MILLIONS)
66
TABLE 27 TOTAL NORTH AMERICAN EXPENDITURES ON THERMAL SPRAY CERAMIC
COATINGS IN AUTOMOTIVE AND DIESEL ENGINES, THROUGH 2018 ($ MILLIONS) 67
TABLE 28 TOTAL NORTH AMERICAN EXPENDITURES ON THERMAL SPRAY CERAMIC
COATINGS FOR MEDICAL APPLICATIONS, THROUGH 2018 ($ MILLIONS) 68
TABLE 29 NORTH AMERICAN CERAMIC THERMAL SPRAY COATING MARKET,
THROUGH 2018 ($ MILLIONS) 68
TABLE 30 MARKET SHARE OF THERMAL SPRAY COATING SERVICE PROVIDERS, 2012
(%) 71
TABLE 31 REPRESENTATIVE FILMS DEPOSITED BY PVD 74
TABLE 32 REPRESENTATIVE PVD SURFACE COATINGS FOR ABRASION- AND
CORROSION-RESISTANT APPLICATIONS 75
TABLE 33 TYPES OF PHYSICAL VAPOR DEPOSITION PROCESSES 77
TABLE 34 BASIC SPUTTERING SOURCES AND PROCESSES 81
TABLE 35 COMPARISON OF MAGNETRON SPUTTERING METHODS FOR DEPOSITING
SIO2 83
TABLE 36 CERAMIC PVD APPLICATIONS 88
TABLE 37 PROPERTIES OF UNCOATED AND TIN-COATED HIGH SPEED STEEL (HSS) 90
TABLE 38 PROPERTIES AND APPLICATION OF VARIOUS BALZERS BALINIT THIN-FILM
WEAR-RESISTANT COATINGS 91
TABLE 39 RECENT DEVELOPMENTS IN PVD 94
TABLE 40 LEADING NORTH AMERICAN COMPANIES MANUFACTURING PVD SYSTEMS
AND/OR PROVIDING SERVICES 96
TABLE 41 NORTH AMERICAN HIGH-PERFORMANCE CERAMIC PVD COATING MARKET,
THROUGH 2018 ($ MILLIONS) 97
TABLE 42 NORTH AMERICAN MARKET FOR CERAMIC PVD TOOL COATINGS,
THROUGH 2018 ($ MILLIONS) 99
TABLE 43 NORTH AMERICAN MARKET FOR CERAMIC COATINGS FOR AUTOMOTIVE,
AEROSPACE AND WEAR-RESISTANT APPLICATIONS, THROUGH 2018 ($ MILLIONS) 99
TABLE 44 NORTH AMERICAN MARKET FOR CERAMIC PVD MEDICAL DEVICE
COATINGS, THROUGH 2018 ($ MILLIONS) 100
TABLE 45 NORTH AMERICAN MARKET FOR CERAMIC PVD MEDICAL DEVICE
COATINGS, THROUGH 2018 ($ MILLIONS) 101
TABLE 46 CERAMICS DEPOSITED BY CVD 104
TABLE 47 TYPICAL CERAMIC CVD COATINGS, PROCESS GASES AND DEPOSITION
TEMPERATURES 106
TABLE 48 CCVD MATERIALS, SUBSTRATES AND APLICAITONS 112
TABLE 49 KEY TECHNICAL ADVANTAGES OF THE CVD PROCESS 112
TABLE 50 KEY TECHNICAL DISADVANTAGES OF THE CVD PROCESS 113
TABLE 51 REPRESENTATIVE CVD CERAMIC COATINGS 113
TABLE 52 OVERVIEW OF CURRENT/EMERGING CUTTING TOOL CVD APPLICATIONS 116
TABLE 53 RECENT DEVELOPMENTS IN CERAMIC CVD COATING 118
TABLE 54 LEADING WORLDWIDE MANUFACTURERS OF CVD EQUIPMENT 119
TABLE 55 LEADING WORLDWIDE CVD SERVICE PROVIDERS 120
TABLE 56 NORTH AMERICAN CERAMIC CVD COATING SERVICE MARKETS BY
APPLICATION, THROUGH 2018 ($ MILLIONS) 121
TABLE 57 NORTH AMERICAN MARKET FOR CERAMIC CVD TOOL INSERT COATINGS,
THROUGH 2018 ($ MILLIONS) 123
TABLE 58 NORTH AMERICAN MARKET FOR CERAMIC CVD WEAR-RESISTANT AND
OTHER INDUSTRIALCOATING APPLICATIONS, THROUGH 2018 ($ MILLIONS) 124
TABLE 60 NORTH AMERICAN MARKET FOR CERAMIC CVD AEROSPACE COATINGS,
THROUGH 2018 ($ MILLIONS) 126
TABLE 62 MARKET SHARE OF CERAMIC CVD COATING SERVICE PROVIDERS, 2010 126
TABLE 63 TEMPERATURE DROP USING COATED HEADERS IN AUTO ENGINES (°F) 131
TABLE 64 APPLICATIONS OF SOL GEL FILMS AND COATINGS 137
TABLE 65 NORTH AMERICAN COMPANIES PROVIDING CERAMIC COATING SERVICES
USING SPRAYING, DIPPING, SOL GEL, LASER AND IONIC BEAM TECHNIQUES 145
TABLE 66 NORTH AMERICAN MARKET FOR OTHER TYPES OF COATING SERVICE BY
APPLICATION, THROUGH 2018 ($ MILLIONS) 148



LIST OF FIGURES

SUMMARY FIGURE F:\BCCRESEARCH\NEW WEBSITE
CONTENT\AVM\2014\AVM015G\IMAGES (% TOTAL MARKET) 8
FIGURE 1 SHARE OF NORTH AMERICAN HIGH-PERFORMANCE CERAMIC COATING
SERVICE MARKET SEGMENTS, 2012-2018 (%) 12
FIGURE 2 PLASMA SPRAY COATING TECHNIQUE 29
FIGURE 3 SCHEMATIC OF HVOF 34
FIGURE 4 SHARE OF NORTH AMERICAN CERAMIC THERMAL SPRAY COATING
SERVICE MARKET SUBSEGMENTS, 2012-2018 (% TOTAL THERMAL SPRAY MARKET) 70
FIGURE 5 COMPARISON OF THE TRS OF UNCOATED AND COATED CARBIDE * (TRS
MPA) 90
FIGURE 6 SHARE OF NORTH AMERICAN CERAMIC THERMAL SPRAY COATING
SERVICE MARKET SUBSEGMENTS, 2012-2018 (% OF TOTAL THERMAL SPRAY
MARKET)
98
FIGURE 7 SUMMARY OF CARBIDE METALCUTTING GRADE DEVELOPMENT 115
FIGURE 8 SHARE OF NORTH AMERICAN CERAMIC CVD COATING SERVICE MARKET
SEGMENTS, 2012-2018 (% OF TOTAL CVD COATING MARKET) 122
FIGURE 9 SHARE OF NORTH AMERICAN CERAMIC COATINGS MARKET USING
SPRAYING/ DIPPING, SOL GEL, MICRO OXIDATION AND LASER-ASSISTED
TECHNIQUES BY APPLICATION, 2012-2018 (%)
149


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High-Performance Ceramic Coatings: Markets and Technologies

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