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1、,MARKET RESEARCH REPORT,HIGH-PERFORMANCE CERAMIC,COATINGS:MARKETS AND,TECHNOLOGIES,AVM015E,Andrew McWilliams,Project Analyst,BCC Research,35 Walnut Street,Wellesley,MA 02481,Phone:866-285-7215(sales),Web Address:,E-mail:,ISBN:1-59623-568-3,ii,AVM015E,HighPerformance Ceramic Coatings:Markets and Tech
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11、Performance Ceramic Coatings:Markets and Technologies,TABLE OF CONTENTSCHAPTER ONE:INTRODUCTION.1STUDY GOALS AND OBJECTIVES.1REASONS FOR DOING THE STUDY.1INTENDED AUDIENCE.2SCOPE OF REPORT.3METHODOLOGY AND INFORMATION SOURCES.4AUTHORS CREDENTIALS.4RELATED BCC REPORTS.4BCC ONLINE SERVICES.5DISCLAIMER
12、.5CHAPTER TWO:EXECUTIVE SUMMARY.6SUMMARY TABLE NORTH AMERICAN MARKET FOR HIGHPERFORMANCE CERAMIC COATINGS BY TYPE OF COATINGTECHNOLOGY,THROUGH 2014($MILLIONS).6SUMMARY FIGURE MARKET SHARE OF NORTH AMERICAN HIGHPERFORMANCE CERAMIC COATING TECHNOLOGIES,20082014(%TOTAL MARKET).7CHAPTER THREE:INDUSTRY O
13、VERVIEW.8INDUSTRY STRUCTURE.8TECHNICAL AND BUSINESS ISSUES.9NORTH AMERICAN MARKETS.9TABLE 1 NORTH AMERICAN MARKET FOR HIGH PERFORMANCECERAMIC COATINGS,BY APPLICATION SEGMENT,THROUGH2014($MILLIONS).9FIGURE 1 SHARE OF NORTH AMERICAN HIGHPERFORMANCECERAMIC COATING SERVICE MARKET SEGMENTS,20082014(%).10
14、INTERNATIONAL COMPETITION.11CHAPTER FOUR:TECHNOLOGY OVERVIEW.12MATERIAL TYPES AND PROPERTIES.12TABLE 2 HIGHPERFORMANCE CERAMIC COATING MATERIALSAND GENERAL APPLICATIONS.12TABLE 3 REPRESENTATIVE FLAME AND PLASMASPRAYEDMATERIALS MELTING OR SOFTENING TEMPERATUREUSES.13TABLE 3(CONTINUED).14TABLE 4 PLASM
15、A SPRAYED CERAMIC COATING PROPERTIES.14TABLE 4(CONTINUED).15COATING TECHNIQUES.15COATING TECHNIQUES(CONTINUED).16Copyright BCC Research,Wellesley,MA USA,Web:,iv,AVM015E,HighPerformance Ceramic Coatings:Markets and Technologies,TABLE OF CONTENTSGENERAL APPLICATIONS.17TABLE 5 LEADING APPLICATIONS OF D
16、EPOSITION BY INDUSTRY.17TABLE 5(CONTINUED).18TABLE 6 TYPICAL COATINGS AND APPLICATIONS.19TABLE 6(CONTINUED).20CHAPTER FIVE:THERMAL SPRAY.21THERMAL SPRAY TECHNIQUES.21COMBUSTION WIRE THERMAL SPRAY PROCESS.21Features and Benefits.22Typical Applications.22COMBUSTION POWDER THERMAL SPRAY PROCESS.23TABLE
17、 7 CERAMIC MATERIALS USED IN THE POWDER FLAMEPROCESS.23Features and Benefits.24Typical Applications.24ELECTRIC ARC WIRE THERMAL SPRAY PROCESS.24Features and Benefits.24Typical Applications.25PLASMA THERMAL SPRAY PROCESS.25Plasma Thermal Spray Process(Continued).26FIGURE 2 PLASMA SPRAY COATING TECHNI
18、QUE.27Plasma Thermal Spray Process(Continued).28Features and Benefits.29Typical Applications.30Supersonic Induction Plasma Torch.31ControlledAtmosphere Plasma Spray Coatings.31Features and Benefits.32Typical Applications.32HVOF THERMAL SPRAY PROCESS.32.FIGURE 3 SCHEMATIC OF HVOF.33HVOF Thermal Spray
19、 Process(Continued).34TABLE 8 PROPERTIES OF HVOF CARBIDE COATINGS.35Features and Benefits.35Typical Applications.35COLD SPRAY PROCESS.36JET KOTE PROCESS.36DETONATION THERMAL SPRAY PROCESS.36PROCESS COMPARISONS.37TABLE 9 COMPARISON OF THERMAL SPRAY PROCESSES.38APPLICATIONS.38Copyright BCC Research,We
20、llesley,MA USA,Web:,v,AVM015E,HighPerformance Ceramic Coatings:Markets and Technologies,TABLE OF CONTENTSAIRCRAFT ENGINES AND AEROSPACE.38Gas Turbine Engines.39Gas Turbine(Continued).40TABLE 10 DETONATION GUN APPLICATIONS IN THE GASTURBINE ENGINE.41TABLE 10(CONTINUED).42TABLE 10(CONTINUED).43TABLE 1
21、0(CONTINUED).44LANDBASED GAS TURBINES.44AUTOMOTIVE COMPONENTS.45Engine Components.46Engine(Continued).47Exhaust Manifolds.48DIESEL ENGINES.48HEAT EXCHANGERS AND BOILERS.49HIGHTEMPERATURE CORROSION RESISTANTAPPLICATIONS.50WEAR RESISTANT AND INDUSTRIAL APPLICATIONS.50MEDICAL.51OTHER EMERGING APPLICATI
22、ONS AND COMPOSITIONS.51TABLE 11 THERMAL SPRAY COATINGS FOR FRPS.52RECENT DEVELOPMENTS.53TABLE 12 RECENT DEVELOPMENTS IN THERMAL SPRAYCOATINGS.53METHOD FOR PREPARING AND ULTRASONICALLYTESTING A THERMALSPRAY COATED ARTICLE.54THERMAL SPRAY COATING OF POROUSNANOSTRUCTURED CERAMIC FEEDSTOCK.54THERMAL SPR
23、AYING POWDER.54FORMATION OF ELECTROCONDUCTIVE LAYER ONALUMINUM ELECTRODE SUPPORT BAR.54CVT HOUSING WITH WEARRESISTANT BORE.55THERMAL COATED PISTON RING.55INSULATING SUBSTRATE AND SEMICONDUCTORDEVICE HAVING A THERMALLY SPRAYED CIRCUITPATTERN.55INDUSTRY STRUCTURE.55NORTH AMERICAN COMPANIES.56TABLE 13
24、LEADING U.S.COMPANIES PROVIDING THERMALSPRAY COATING SERVICES FOR OEM PARTS.57Copyright BCC Research,Wellesley,MA USA,Web:,vi,AVM015E,HighPerformance Ceramic Coatings:Markets and Technologies,TABLE OF CONTENTSTABLE 14 NORTH AMERICAN CUSTOM/JOB SHOPS PROVIDINGTHERMALSPRAY COATING SERVICES.57TABLE 14(
25、CONTINUED).58TABLE 15 LEADING U.S.COMPANIES PROVIDING THERMALSPRAY COATING CONSUMABLES.58TABLE 16 U.S.COMPANIES SUPPLYING CONSUMABLES FORNANOCERAMIC COATINGS.59TABLE 17 U.S.MANUFACTURERS OF PLASMA SPRAY EQUIPMENT.59ACQUISITIONS,MERGERS AND OTHER BUSINESSRELATIONSHIPS.59TABLE 18 ACQUISITIONS,MERGERS
26、AND OTHER BUSINESSRELATIONS IN THE THERMALSPRAY INDUSTRY SINCE 1990.60NORTH AMERICAN MARKETS.60TURBINE ENGINES OEM AND OVERHAUL.60Aircraft Engines.60TABLE 19 TOTAL NORTH AMERICAN EXPENDITURES ONTHERMAL SPRAY CERAMIC COATING OF AIRCRAFT GASTURBINE PARTS,THROUGH 2014($MILLIONS).61TABLE 20 NORTH AMERIC
27、AN SHIPMENTS OF TURBOFAN,TURBOPROP,AND TURBOSHAFT ENGINES,THROUGH 2014(NUMBER OF ENGINES).61Aircraft Engines(Continued).62TABLE 21 COST OF AIRCRAFT ENGINE COATING SERVICES,THROUGH 2014($MILLIONS).63TABLE 22 NORTH AMERICAN AIRCRAFT GAS TURBINE ENGINEOVERHAUL MARKET THROUGH 2014($MILLIONS).64LandBased
28、 Turbines.64TABLE 23 TOTAL NORTH AMERICAN EXPENDITURES ONTHERMAL SPRAY CERAMIC COATING OF LARGE LANDBASEDTURBINE PARTS,THROUGH 2014($MILLIONS).64TABLE 24 COST OF NEW LARGE LANDBASED TURBINE COATINGSERVICES,THROUGH 2014($MILLIONS).65TABLE 25 COST OF LARGE LANDBASED TURBINEREFURBISHMENT COATING SERVIC
29、ES,THROUGH 2014($MILLIONS).66WEAR RESISTANT PARTS AND INDUSTRIALAPPLICATIONS.66TABLE 26 TOTAL NORTH AMERICAN EXPENDITURES ONTHERMAL SPRAY CERAMIC COATING OF WEAR RESISTANTPARTS AND INDUSTRIAL APPLICATIONS,THROUGH 2014($MILLIONS).67Copyright BCC Research,Wellesley,MA USA,Web:,vii,AVM015E,HighPerforma
30、nce Ceramic Coatings:Markets and Technologies,TABLE OF CONTENTSAUTOMOTIVE AND DIESEL ENGINES.67Automotive and Diesel Engines(Continued).68TABLE 27 NORTH AMERICAN EXPENDITURES ON THERMALSPRAY CERAMIC COATINGS IN AUTOMOTIVE AND DIESELENGINES,THROUGH 2014($MILLIONS).69MEDICAL.69TABLE 28 TOTAL NORTH AME
31、RICAN EXPENDITURES ONTHERMAL SPRAY CERAMIC COATINGS FOR MEDICALAPPLICATIONS,THROUGH 2014($MILLIONS).70HEAT EXCHANGERS AND HIGH TEMPERATURE.70OTHER APPLICATIONS.70MARKET AND MARKET SHARES.70TABLE 29 NORTH AMERICAN CERAMIC THERMAL SPRAYCOATING MARKET,THROUGH 2014($MILLIONS).71FIGURE 4 SHARE OF NORTH A
32、MERICAN CERAMIC THERMALSPRAY COATING SERVICE MARKET SUBSEGMENTS,20082014.72MARKET SHARE OF COMPANIES.73TABLE 30 MARKET SHARE OF THERMAL SPRAY COATINGSERVICE PROVIDERS(%).73CHAPTER SIX:PHYSICAL VAPOR DEPOSITION(PVD).74BASIC PRINCIPLES.74PVD MATERIALS.75TABLE 31 REPRESENTATIVE FILMS DEPOSITED BY PVD.7
33、5TABLE 32 REPRESENTATIVE PVD SURFACE COATINGS FORABRASION AND CORROSION RESISTANT APPLICATIONS.76TITANIUM NITRIDE COATING(TIN).76TITANIUM CARBO NITRIDE COATING(TICN).77TITANIUM ALUMINUM NITRIDE COATING(TIALN).77TITANIUM DIBORIDE COATING(TIB2).77TIALNX.77CHROMIUM NITRIDE COATING(CRN).77SUPERR COATING
34、.78ZIRCONIUM NITRIDE COATING(ZRN).78PVD TECHNOLOGIES.78TABLE 33 TYPES OF PHYSICAL VAPOR DEPOSITION PROCESSES.78PVD BY EVAPORATION.79Evaporation Sources.79Evaporation Deposition Processes.80Thermal Evaporation.81Electronbeam Evaporation.81Copyright BCC Research,Wellesley,MA USA,Web:,viii,AVM015E,High
35、Performance Ceramic Coatings:Markets and Technologies,TABLE OF CONTENTSPVD ARC PROCESS.82PVD BY SPUTTERING.82Sputtering Sources and Processes.83TABLE 34 BASIC SPUTTERING SOURCES AND PROCESSES.83Direct Current(DC)Diode Sputtering.84Triode Sputtering.84Radio Frequency(RF)Sputtering.84Magnetron Sputter
36、ing.85TABLE 35 COMPARISON OF MAGNETRON SPUTTERING METHODSFOR DEPOSITING SIO2.85Linear Magnetron Sputtering.86Unbalanced Magnetron Sputtering.86Ion Beam Sputtering.86Sputter Ion Plating(SIP)Process.87Cosputtering.88Reactive Sputtering.88COMPARISON OF EVAPORATION AND SPUTTERING.89MULTICHAMBER SYSTEM.9
37、0PVD ADVANTAGES AND LIMITATIONS.91PVD APPLICATIONS.91TABLE 36 CERAMIC PVD APPLICATIONS.92TOOLS.92Tools(Continued).93TABLE 37 PROPERTIES OF UNCOATED AND TIN COATED HSS.94FIGURE 5 A COMPARISON OF THE TRS OF UNCOATED ANDCOATED CARBIDE AS MEASURED BY THE THREEPOINT BENDTEST ON 0.2 X 0.2 X 0.75 INCH SPEC
38、IMENS.95TABLE 38 PROPERTIES AND APPLICATION OF VARIOUS BALZERSBALINIT THIN FILM WEARRESISTANT COATINGS.96Tools(Continued).97TURBINE VANES AND BLADES.97RECENT DEVELOPMENTS.98TABLE 39 RECENT DEVELOPMENTS IN PVD.98METHOD TO PREVENT LOW TEMPERATUREDEGRADATION OF ZIRCONIA.99CERAMIC COATINGS FOR INSULATIN
39、G MODULAR FUELCELL CASSETTES IN A SOLIDOXIDE FUEL CELLSTACK.99THERMAL BARRIER COATING RESISTANT TOPENETRATION BY ENVIRONMENTAL CONTAMINANTS.99Copyright BCC Research,Wellesley,MA USA,Web:,ix,AVM015E,HighPerformance Ceramic Coatings:Markets and Technologies,TABLE OF CONTENTSOXIDATION BARRIER COATINGS
40、FOR SILICON BASEDCERAMICS.100INDUSTRY STRUCTURE.100NORTH AMERICAN COMPANIES.100TABLE 40 LEADING NORTH AMERICAN COMPANIESMANUFACTURING PVD SYSTEMS AND/OR PROVIDINGSERVICES.101NORTH AMERICAN MARKETS.102TABLE 41 NORTH AMERICAN HIGHPERFORMANCE CERAMICPVD COATING MARKET,THROUGH 2014($MILLIONS).102FIGURE
41、6 SHARE OF NORTH AMERICAN CERAMIC THERMALSPRAY COATING SERVICE MARKET SUBSEGMENTS,20082014(%OF TOTAL THERMAL SPRAY MARKET).103TOOLS.103TABLE 42 NORTH AMERICAN MARKET FOR CERAMIC PVD TOOLCOATINGS,THROUGH 2014($MILLIONS).104INDUSTRIAL SERVICES.104TABLE 43 NORTH AMERICAN MARKET FOR CERAMIC COATINGSFOR
42、AUTOMOTIVE,AEROSPACE AND WEARRESISTANTAPPLICATIONS,THROUGH 2014($MILLIONS).105MEDICAL.105TABLE 44 NORTH AMERICAN MARKET FOR CERAMIC PVDMEDICAL DEVICE COATINGS,20082014($MILLIONS).106MARKET SHARE OF COMPANIES.106TABLE 45 MARKET SHARE OF CERAMCI PVD COATING SERVICEPROVIDERS,2008(%).106CHAPTER SEVEN:CH
43、EMICAL VAPOR DEPOSITION(CVD).107BASIC PRINCIPLE.107CVD MATERIALS.108TABLE 46 CERAMICS DEPOSITED BY CVD.108TABLE 46(CONTINUED).109TABLE 46(CONTINUED).110CVD TECHNIQUES.110TABLE 47 TYPICAL CERAMIC CVD COATINGS,PROCESS GASESAND DEPOSITION TEMPERATURES.110BASIC THERMAL CVD PROCESS.111MetalloOrganic CVD(
44、MOCVD).111Atmospheric Pressure CVD.112LowPressure CVD.112PLASMAASSISTED CVD.113Copyright BCC Research,Wellesley,MA USA,Web:,x,AVM015E,HighPerformance Ceramic Coatings:Markets and Technologies,TABLE OF CONTENTSDC Plasma Method.113RF Induction Plasma.114Microwave Plasma Torch.114Cathodicarc Plasma Dep
45、osition.114Highenergy Intensified Plasmaassisted Processing(HEIPAP).115COMBUSTION CHEMICAL VAPOR DEPOSITON(CCVD).116TABLE 48 CCVD MATERIALS,SUBSTRATES AND APLICAITONS.117ADVANTAGES AND DISADVANTAGES OF CVD.117TABLE 49 KEY TECHNICAL ADVANTAGES OF THE CVD PROCESS.118TABLE 50 KEY TECHNICAL DISADVANTAGE
46、S OF THE CVDPROCESS.118CVD APPLICATIONS.118TABLE 51 REPRESENTATIVE CVD CERAMIC COATINGS.119CUTTING TOOLS.119Cutting Tools(Continued).120FIGURE 7 SUMMARY OF CARBIDE METALCUTTING GRADEDEVELOPMENT.121TABLE 52 OVERVIEW OF CURRENT/EMERGING CUTTING TOOLCVD APPLICATIONS.122INDUSTRIAL APPLICATIONS.123AEROSP
47、ACE.123HIGHTEMPERATURE APPLICATIONS.124FOULINGRESISTANT CERAMIC MEMBRANES.124NEW DEVELOPMENTS.124TABLE 53 RECENT DEVELOPMENTS IN CERAMIC CVD COATING.125PIEZOELECTRIC/ELECTROSTRICTIVE STRUCTURE ANDMETHOD FOR MANUFACTURING THE SAME.125INDUSTRY STRUCTURE.125LEADING CVD SYSTEMS MANUFACTURERS.126TABLE 54
48、 LEADING WORLDWIDE MANUFACTURERS OF CVDEQUIPMENT.126LEADING CVD SERVICE PROVIDERS.127TABLE 55 LEADING WORLDWIDE CVD SERVICE PROVIDERS.127NORTH AMERICAN MARKET.128TABLE 56 NORTH AMERICAN CERAMIC CVD COATING SERVICEMARKETS BY APPLICATION,THROUGH 2014($MILLIONS).129FIGURE 8 SHARE OF NORTH AMERICAN CERA
49、MIC CVD COATINGSERVICE MARKET SEGMENTS,20082014(%OF TOTAL CVDCOATING MARKET).130TOOLS.130Copyright BCC Research,Wellesley,MA USA,Web:,xi,AVM015E,HighPerformance Ceramic Coatings:Markets and Technologies,TABLE OF CONTENTSTABLE 57 NORTH AMERICAN MARKET FOR CERAMIC CVD TOOLINSERT COATINGS,THROUGH 2014(
50、$MILLIONS).131WEARRESISTANT AND INDUSTRIAL APPLICATIONS.131TABLE 58 NORTH AMERICAN MARKET FOR CERAMIC CVD WEARRESISTANT AND OTHER INDUSTRIALCOATING APPLICATIONS,THROUGH 2014($MILLIONS).132AUTOMOTIVE.132Automotive(Continued).133TABLE 59 NORTH AMERICAN MARKET FOR CERAMIC CVDAUTOMOTIVE COMPONENT COATIN
