High-Performance Ceramic Coatings: Markets and Technologies

Published - Feb 2010| Analyst - Andrew McWilliams| Code - AVM015E
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Report Highlights

  • The North American market for high–performance ceramic coatings was worth an estimated $1.42 billion in 2008.  This figure is expected to fall slightly to $1.4 billion for 2009, but should rise to more than $2.0 billion by 2014 at a projected 5–year compound annual growth rate (CAGR) of 7.6%.
  • Thermal spray coatings dominate the market, with about 67% of total sales in 2008, projected to increase to 70% by 2014. The value of this sector was $953 million in 2009 and will reach an estimated $1.4 billion by 2014, a compound annual growth rate (CAGR) of 8.1%.
  • CVD accounted for the second–largest share of the market in 2008 at 15%, but is expected to drop into third place behind PVD with 11% of the market in 2014. The CVD market was worth $183.4 million in 2009 and will increase to an estimated $220.7 million in 2014, a compound annual growth rate (CAGR) of 3.8%.

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 2007, significant changes have taken place in the ceramic coating service industry. In view of these changes, BCC decided that there is now 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 among ceramic thermal spray, PVD, CVD and other coating techniques 
  • Identify the users of ceramic coating services. 
REASONS FOR DOING 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 in their form and the preparation techniques required. However, their uses are diverse, and they exploit the 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 the life of uncoated inserts. This, in turn, has reduced the cost of cutting tool inserts, and at the same time has increased productivity. Similarly, ceramic–coated components for aircraft turbine engines resulted in building large aircraft. Now, auto enthusiasts are coating certain auto engine components to improve auto engine performance. Also, ceramic coatings have made it possible for certain large machine components to be repaired in situ. 
INTENDED AUDIENCE
 
This new BCC study provides an in–depth analysis of the materials, applications, economics, current markets and trends, and the players. Forecasts are provided for each major market segment through 2014. 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 hopes to provide a better understanding of the North American ceramics 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 to 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 doing repair and refurbishing of aircraft engines
  • Producers of automotive and diesel engines
  • Job shops providing coating services to racing car 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 OF REPORT
 
This BCC study has been 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 2008 U.S. dollars. 
The report provides business planners and managers with an improved understanding of the direction and impact of the 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 the 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 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. Both primary and secondary research methodologies were using 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 of the coating service providers and end users were contacted to evaluate current and future demands for these coatings. 
More than 200 industry contacts assisted BCC in identifying and updating technologies and applications. In addition to utilizing its in-house database on ceramic coatings, BCC conducted extensive Web searches to gather and analyze all pertinent information related to this study. Major technical and trade publications and conference proceedings in ceramic coatings were also used for this study.
AUTHORS CREDENTIALS
This report is an update of an earlier (2004) report prepared by Dr. Thomas Abraham.  Dr. Abraham was formerly Vice President and Director of the Advanced Materials Group of BCC.  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 studies, including studies in related fields such as AVM025F Diamond, Diamond–Like and CBN Films and Coating Products; NAN015E Advanced Ceramics and Nano Ceramic Powders; NAN021D  Nanocomposites, Nanoparticles, Nanoclays, and Nanotubes;  NAN040A Nanomaterials Markets by Type; and AVM008B Synthetic Gems and Minerals.
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DISCLAIMER
The information developed in this report is intended to be as reliable as possible at the time of publication and of a professional nature. This information does not constitute managerial, legal, or accounting advice; nor should it serve as a corporate policy guide, laboratory manual, or an endorsement of any product, as much of the information is speculative in nature. The author assumes no responsibility for any loss or damage that might result from reliance on the reported information or its use.

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Published - Sep-2007| Analyst - Andrew McWilliams| Code - AVM015D

Report Highlights

  • The North American market for high-performance ceramic coatings was an astimated $1.3 billion in 2006. This figure is expected to rise to nearly $1.4 billion in 2007 and $1.9 billion by 2012, a projected compound annual growth rate of 6.0% over the next five years.
  • Thermal spray coatings dominate the market, with about 65% of total sales. CVD accounts for the second-largest share of the market with nearly 16% in 2006, although this percentage is expected to decline slightly to 14% by 2012.
  • The share of PVD, the third-largest technology segment, is projected to remain rougly steady at slightly over 12% between 2006 and 2012.
Published - Dec-2004| Analyst - Thomas Abraham| Code - AVM015C

Report Highlights

  • The North American market for high-performance ceramic coating services in 2004 is estimated at $1.1 billion. This is expected to increase to $1.6 billion by 2009 at an annual average growth rate (AAGR) of 7.6%.
  • Thermal spray coatings will register an AAGR of 8.5% due to increased demand for commercial and military aircraft in the next five years led by demand in Asia
  • PVD and CVD will register lower growth rates (5.8% and 5.0%, respectively) over the next five years.
  • In 2004, about 64% of the market belonged to the coating of engine components. Cutting and turning tools contributed about 17% of the market and wear-resistant and industrial parts, 14.6%. By 2009, engine applications will rise to 68%.

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