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1、MARKET RESEARCH REPORTHIGH-PERFORMANCE CERAMICCOATINGS: MARKETS ANDTECHNOLOGIESAVM015EAndrew McWilliamsProject AnalystBCC Research35 Walnut StreetWellesley, MA 02481Phone: 866-285-7215 (sales)Web Address: E-mail: ISBN: 1-59623-568-3iiAVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesT

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10、e on this material.Copyright 2009 by BCC Research Wellesley, MA 02481Reproduction of any material in this report is strictly forbidden without express permission of thePublisher.To receive a complete catalog of BCC studies, please visit our Web site at FEBRUARY 2010Copyright BCC Research, Wellesley,

11、 MA USA, Web: iiiAVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesTABLE 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

12、REPORTS . 4BCC ONLINE SERVICES. 5DISCLAIMER . 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 TECHNOLOGI

13、ES, 20082014(% TOTAL MARKET) . 7CHAPTER THREE: INDUSTRY OVERVIEW. 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 H

14、IGHPERFORMANCECERAMIC COATING SERVICE MARKET SEGMENTS, 20082014(%) . 10INTERNATIONAL COMPETITION . 11CHAPTER FOUR: TECHNOLOGY OVERVIEW . 12MATERIAL TYPES AND PROPERTIES . 12TABLE 2 HIGHPERFORMANCE CERAMIC COATING MATERIALSAND GENERAL APPLICATIONS. 12TABLE 3 REPRESENTATIVE FLAME AND PLASMASPRAYEDMATE

15、RIALS MELTING OR SOFTENING TEMPERATUREUSES . 13TABLE 3 (CONTINUED). 14TABLE 4 PLASMA SPRAYED CERAMIC COATING PROPERTIES. 14TABLE 4 (CONTINUED). 15COATING TECHNIQUES. 15COATING TECHNIQUES (CONTINUED) . 16Copyright BCC Research, Wellesley, MA USA, Web: ivAVM015EHighPerformance Ceramic Coatings: Market

16、s and TechnologiesTABLE OF CONTENTSGENERAL APPLICATIONS. 17TABLE 5 LEADING APPLICATIONS OF DEPOSITION 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 PR

17、OCESS . 21Features and Benefits . 22Typical Applications . 22COMBUSTION POWDER THERMAL SPRAY PROCESS. 23TABLE 7 CERAMIC MATERIALS USED IN THE POWDER FLAMEPROCESS. 23Features and Benefits . 24Typical Applications . 24ELECTRIC ARC WIRE THERMAL SPRAY PROCESS . 24Features and Benefits . 24Typical Applic

18、ations . 25PLASMA THERMAL SPRAY PROCESS. 25Plasma Thermal Spray Process (Continued). 26FIGURE 2 PLASMA SPRAY COATING TECHNIQUE. 27Plasma Thermal Spray Process (Continued). 28Features and Benefits . 29Typical Applications . 30Supersonic Induction Plasma Torch . 31ControlledAtmosphere Plasma Spray Coa

19、tings. 31Features and Benefits. 32Typical Applications . 32HVOF THERMAL SPRAY PROCESS . 32.FIGURE 3 SCHEMATIC OF HVOF . 33HVOF Thermal Spray Process (Continued) . 34TABLE 8 PROPERTIES OF HVOF CARBIDE COATINGS . 35Features and Benefits . 35Typical Applications . 35COLD SPRAY PROCESS . 36JET KOTE PROC

20、ESS. 36DETONATION THERMAL SPRAY PROCESS. 36PROCESS COMPARISONS . 37TABLE 9 COMPARISON OF THERMAL SPRAY PROCESSES . 38APPLICATIONS . 38Copyright BCC Research, Wellesley, MA USA, Web: vAVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesTABLE OF CONTENTSAIRCRAFT ENGINES AND AEROSPACE . 38

21、Gas Turbine Engines. 39Gas Turbine (Continued) . 40TABLE 10 DETONATION GUN APPLICATIONS IN THE GASTURBINE ENGINE. 41TABLE 10 (CONTINUED). 42TABLE 10 (CONTINUED). 43TABLE 10 (CONTINUED). 44LANDBASED GAS TURBINES . 44AUTOMOTIVE COMPONENTS . 45Engine Components. 46Engine (Continued) . 47Exhaust Manifol

22、ds. 48DIESEL ENGINES . 48HEAT EXCHANGERS AND BOILERS . 49HIGHTEMPERATURE CORROSION RESISTANTAPPLICATIONS . 50WEAR RESISTANT AND INDUSTRIAL APPLICATIONS . 50MEDICAL . 51OTHER EMERGING APPLICATIONS AND COMPOSITIONS. 51TABLE 11 THERMAL SPRAY COATINGS FOR FRPS. 52RECENT DEVELOPMENTS . 53TABLE 12 RECENT

23、DEVELOPMENTS IN THERMAL SPRAYCOATINGS. 53METHOD FOR PREPARING AND ULTRASONICALLYTESTING A THERMALSPRAY COATED ARTICLE. 54THERMAL SPRAY COATING OF POROUSNANOSTRUCTURED CERAMIC FEEDSTOCK . 54THERMAL SPRAYING POWDER. 54FORMATION OF ELECTROCONDUCTIVE LAYER ONALUMINUM ELECTRODE SUPPORT BAR. 54CVT HOUSING

24、 WITH WEARRESISTANT BORE. 55THERMAL COATED PISTON RING . 55INSULATING SUBSTRATE AND SEMICONDUCTORDEVICE HAVING A THERMALLY SPRAYED CIRCUITPATTERN. 55INDUSTRY STRUCTURE . 55NORTH AMERICAN COMPANIES. 56TABLE 13 LEADING U.S. COMPANIES PROVIDING THERMALSPRAY COATING SERVICES FOR OEM PARTS. 57Copyright B

25、CC Research, Wellesley, MA USA, Web: viAVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesTABLE OF CONTENTSTABLE 14 NORTH AMERICAN CUSTOM/JOB SHOPS PROVIDINGTHERMALSPRAY COATING SERVICES. 57TABLE 14 (CONTINUED). 58TABLE 15 LEADING U.S. COMPANIES PROVIDING THERMALSPRAY COATING CONSUMABL

26、ES . 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 AND OTHER BUSINESSRELATIONS IN THE THERMALSPRAY INDUSTRY SINCE 1990 . 60NO

27、RTH 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 AMERICAN SHIPMENTS OF TURBOFAN,TURBOPROP, AND TURBOSHAFT ENGINES, THRO

28、UGH 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 Turbines . 64TABLE 23 TOTAL NORTH AMERICAN EXPEND

29、ITURES 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 SERVICES, THROUGH 2014 ($MILLIONS) . 66WEAR R

30、ESISTANT 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: viiAVM015EHighPerformance Ceramic Coatings: Market

31、s and TechnologiesTABLE 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 AMERICAN EXPENDITURE

32、S 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 AMERI

33、CAN 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 DEPOSI

34、TED BY PVD . 75TABLE 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 COAT

35、ING (CRN). 77SUPERR COATING . 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 Resea

36、rch, Wellesley, MA USA, Web: viiiAVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesTABLE OF CONTENTSPVD ARC PROCESS. 82PVD BY SPUTTERING . 82Sputtering Sources and Processes . 83TABLE 34 BASIC SPUTTERING SOURCES AND PROCESSES. 83Direct Current (DC) Diode Sputtering . 84Triode Sputteri

37、ng . 84Radio Frequency (RF) Sputtering. 84Magnetron Sputtering . 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 Spu

38、ttering. 88COMPARISON OF EVAPORATION AND SPUTTERING . 89MULTICHAMBER SYSTEM. 90PVD 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 UNCOATE

39、D ANDCOATED CARBIDE AS MEASURED BY THE THREEPOINT BENDTEST ON 0.2 X 0.2 X 0.75 INCH SPECIMENS. 95TABLE 38 PROPERTIES AND APPLICATION OF VARIOUS BALZERSBALINIT THIN FILM WEARRESISTANT COATINGS . 96Tools (Continued). 97TURBINE VANES AND BLADES . 97RECENT DEVELOPMENTS . 98TABLE 39 RECENT DEVELOPMENTS I

40、N PVD. 98METHOD TO PREVENT LOW TEMPERATUREDEGRADATION OF ZIRCONIA . 99CERAMIC COATINGS FOR INSULATING MODULAR FUELCELL CASSETTES IN A SOLIDOXIDE FUEL CELLSTACK. 99THERMAL BARRIER COATING RESISTANT TOPENETRATION BY ENVIRONMENTAL CONTAMINANTS. 99Copyright BCC Research, Wellesley, MA USA, Web: ixAVM015

41、EHighPerformance Ceramic Coatings: Markets and TechnologiesTABLE OF CONTENTSOXIDATION BARRIER COATINGS FOR SILICON BASEDCERAMICS . 100INDUSTRY STRUCTURE . 100NORTH AMERICAN COMPANIES. 100TABLE 40 LEADING NORTH AMERICAN COMPANIESMANUFACTURING PVD SYSTEMS AND/OR PROVIDINGSERVICES . 101NORTH AMERICAN M

42、ARKETS. 102TABLE 41 NORTH AMERICAN HIGHPERFORMANCE CERAMICPVD COATING MARKET, THROUGH 2014 ($ MILLIONS) . 102FIGURE 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

43、PVD TOOLCOATINGS, THROUGH 2014 ($ MILLIONS). 104INDUSTRIAL SERVICES . 104TABLE 43 NORTH AMERICAN MARKET FOR CERAMIC COATINGSFOR AUTOMOTIVE, AEROSPACE AND WEARRESISTANTAPPLICATIONS, THROUGH 2014 ($ MILLIONS) . 105MEDICAL . 105TABLE 44 NORTH AMERICAN MARKET FOR CERAMIC PVDMEDICAL DEVICE COATINGS, 2008

44、2014 ($ MILLIONS) . 106MARKET SHARE OF COMPANIES . 106TABLE 45 MARKET SHARE OF CERAMCI PVD COATING SERVICEPROVIDERS, 2008 (%) . 106CHAPTER SEVEN: CHEMICAL VAPOR DEPOSITION (CVD). 107BASIC PRINCIPLE . 107CVD MATERIALS . 108TABLE 46 CERAMICS DEPOSITED BY CVD . 108TABLE 46 (CONTINUED). 109TABLE 46 (CON

45、TINUED). 110CVD TECHNIQUES . 110TABLE 47 TYPICAL CERAMIC CVD COATINGS, PROCESS GASESAND DEPOSITION TEMPERATURES. 110BASIC THERMAL CVD PROCESS . 111MetalloOrganic CVD (MOCVD). 111Atmospheric Pressure CVD. 112LowPressure CVD . 112PLASMAASSISTED CVD. 113Copyright BCC Research, Wellesley, MA USA, Web: x

46、AVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesTABLE OF CONTENTSDC Plasma Method. 113RF Induction Plasma. 114Microwave Plasma Torch . 114Cathodicarc Plasma Deposition . 114Highenergy Intensified Plasmaassisted Processing(HEIPAP). 115COMBUSTION CHEMICAL VAPOR DEPOSITON (CCVD) . 116T

47、ABLE 48 CCVD MATERIALS, SUBSTRATES AND APLICAITONS . 117ADVANTAGES AND DISADVANTAGES OF CVD. 117TABLE 49 KEY TECHNICAL ADVANTAGES OF THE CVD PROCESS. 118TABLE 50 KEY TECHNICAL DISADVANTAGES OF THE CVDPROCESS. 118CVD APPLICATIONS . 118TABLE 51 REPRESENTATIVE CVD CERAMIC COATINGS . 119CUTTING TOOLS. 1

48、19Cutting Tools (Continued). 120FIGURE 7 SUMMARY OF CARBIDE METALCUTTING GRADEDEVELOPMENT . 121TABLE 52 OVERVIEW OF CURRENT/EMERGING CUTTING TOOLCVD APPLICATIONS . 122INDUSTRIAL APPLICATIONS . 123AEROSPACE. 123HIGHTEMPERATURE APPLICATIONS . 124FOULINGRESISTANT CERAMIC MEMBRANES . 124NEW DEVELOPMENTS

49、. 124TABLE 53 RECENT DEVELOPMENTS IN CERAMIC CVD COATING. 125PIEZOELECTRIC/ELECTROSTRICTIVE STRUCTURE ANDMETHOD FOR MANUFACTURING THE SAME. 125INDUSTRY STRUCTURE . 125LEADING CVD SYSTEMS MANUFACTURERS . 126TABLE 54 LEADING WORLDWIDE MANUFACTURERS OF CVDEQUIPMENT . 126LEADING CVD SERVICE PROVIDERS. 1

50、27TABLE 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 CERAMIC CVD COATINGSERVICE MARKET SEGMENTS, 20082014 (% OF TOTAL CVDCOATING MAR

51、KET). 130TOOLS . 130Copyright BCC Research, Wellesley, MA USA, Web: xiAVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesTABLE OF CONTENTSTABLE 57 NORTH AMERICAN MARKET FOR CERAMIC CVD TOOLINSERT COATINGS, THROUGH 2014 ($ MILLIONS) . 131WEARRESISTANT AND INDUSTRIAL APPLICATIONS . 131TA

52、BLE 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 COATINGS, THROUGH 2014 ($MILLIONS) . 134AIRCRAFT AND AEROSPA

53、CE . 134TABLE 60 NORTH AMERICAN MARKET FOR CERAMIC CVDAEROSPACE COATINGS, THROUGH 2014 ($ MILLIONS). 135MEDICAL . 135TABLE 61 NORTH AMERICAN MARKET FOR CERAMIC CVDMEDICAL DEVICE COATINGS, THROUGH 2014 ($ MILLIONS). 136MARKET SHARE OF COMPANIES . 137TABLE 62 MARKET SHARE OF CERAMIC CVD COATING SERVIC

54、EPROVIDERS (%) . 137CHAPTER EIGHT: OTHER COATING TECHNIQUES. 138SPRAYING, BRUSH PAINTING, AND DIPPING . 138SPRAYING . 139Metallic Ceramic Coating. 139Ceramic Coating . 139Thermal Barrier Coating. 140DryFilm Coating. 140TABLE 63 TEMPERATURE DROP USING COATED HEADERS INAUTO ENGINES (F) . 141PAINTING W

55、ITH A BRUSH. 142DIPPING. 142REPCOAT PROCESS . 142COATING UTILITIES . 143HighTemperature and CorrosionResistant Coatings . 143High Temperature Insulative Coating . 144CEMENTATION. 145PACK CEMENTATION. 145FluidizedBed Cementation Process . 146VaporStream Cementation . 146SOL GEL PROCESSING. 147Copyrig

56、ht BCC Research, Wellesley, MA USA, Web: xiiAVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesTABLE OF CONTENTSTABLE 64 APPLICATIONS OF SOL GEL FILMS AND COATINGS. 147DATEC PROCESS . 148USING LASERS FOR COATING . 149PULSED LASER DEPOSITION (PLD) . 150LASER ASSISTED ATMOSPHERIC PLASMA

57、SPRAYING. 151QQC PROCESS . 151ION BEAMASSISTED DEPOSITION (IBAD) . 151ION BEAM SURFACE TREATMENT (IBEST) . 152ION BEAM ENHANCED DEPOSITION (IBED). 153MICRODISCHARGE DEPOSITION . 154MICROPLASMIC COATING . 155INDUSTRY STRUCTURE . 156NORTH AMERICAN COMPANIES. 156TABLE 65 NORTH AMERICAN COMPANIES PROVID

58、ING CERAMICCOATING SERVICES USING SPRAYING, DIPPING, SOL GEL,LASER AND IONIC BEAM TECHNIQUES . 157North American Companies (Continued) . 158NORTH AMERICAN MARKET. 159SPRAYING/BRUSH PAINTING/DIPPING . 159Spraying/Brush Painting/Dipping (continued). 160TABLE 66 NORTH AMERICAN CERAMIC CVD COATING OTHER

59、SERVICE MARKETS BY APPLICATION, THROUGH 2014 ($MILLIONS) . 161FIGURE 9 SHARE OF NORTH AMERICAN CERAMIC COATINGSMARKET USING SPRAYING/DIPPING, SOL GEL, MICROOXIDATION AND LASERASSISTED TECHNIQUES BYAPPLICATION, 20082014 (%). 162MARKET SHARE OF COMPANIES . 163CHAPTER NINE: COMPANY PROFILES . 164PROFIL

60、ES OF NORTH AMERICAN COMPANIES INVOLVED INCERAMIC COATINGS AS EQUIPMENT MANUFACTURERS,SUPPLIERS OF CONSUMABLES, COATING SERVICEPROVIDERS AND USERS . 164A&A COMPANY, INC. 164ACCESSORIES PLUS . 164ACCUWRIGHT INDUSTRIES, INC. 164ADVANCED CUTTING TOOLS, INC. . 165AERO TURBINE, INC. 165AESTHETIC FINISHER

61、S INC. . 165AIR PRODUCTS & CHEMICALS, INC. 166Copyright BCC Research, Wellesley, MA USA, Web: xiiiAVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesTABLE OF CONTENTSALPHA TECH COATINGS (ATC), INC. 167AMERICAN ROLLER CO. . 167APPLIED MATERIALS . 168APS MATERIALS . 168AREMCO PRODUCTS IN

62、C. 169ASB INDUSTRIES. 170BENDER MACHINE CO. 170CERAMIC COATING, INC. 171CETEK LIMITED . 171CHEMAT TECHNOLOGY INC. 172CHROMALLOY GAS TURBINE LLC . 172CHROMALLOY NEW YORK . 173CINCINNATI THERMAL SPRAY . 174COTRONICS CORP. . 175CVD EQUIPMENT CORP. . 175DATEC COATING CORP. . 175DENTON VACUUM . 176ELLISO

63、N SURFACE TECHNOLOGIES. 177ENGELHARD SURFACE TECHNOLOGIES/BASF . 177ENVIRONMENTAL ABRASIVES . 178EUTECTIC CORP. . 178EXLINE INC. . 179FREECOM INC. 179Freecom Inc. (Continued) . 180F.W. GARTNER THERMAL SPRAYING CO. 181FFWD CONNECTION. 182FLAME SPRAY COATING CO. INC. . 182FLAME SPRAY INC. . 182GENERAL

64、 ELECTRIC CO. 183GENERAL MAGNAPLATE CORP. . 183GOLD STAR COATINGS/BALZERS . 183GRENCO INDUSTRIES, LTD. . 184GSEM, INC. 184HAYDEN CORP. . 185HEANY INDUSTRIES, INC. 185HFW INDUSTRIES, INC. . 186HIGH PERFORMANCE COATINGS . 186HITEMCO. 186HONEYWELL AEROSPACE . 187HOWMET CASTING SPECIAL PRODUCTS . 187HOW

65、MET CASTINGS THERMATECH COATINGS . 188Copyright BCC Research, Wellesley, MA USA, Web: xivAVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesTABLE OF CONTENTSHOWMET TURBINE COMPONENTS COATINGS . 188INDUSTRIAL GRINDING . 189INDUSTRIAL MACHINE & MFG., LTD. 189INFRAMAT CORP. . 189INGERSOLL

66、 CUTTING TOOL COMPANY. 190IONBOND INC. 190JETHOT COATINGS. 191KENNAMETAL, INC. 191MER CORP. 192NGIMAT CO. 193MICROPLASMIC CORPORATION . 194MUSCLE SHOALS MINERALS . 194NANOPHASE TECHNOLOGIES, INC. . 195NATIONAL THERMOSPRAY INC. 195NORTHWEST METTECH CORP. . 196OERLIKON USA. 197PETERS PERFORMANCE CERAM

67、IC COATING . 197PLASMA COATINGS, INC . 198PLASMA TECHNOLOGY, INC. 198PRATT & WHITNEY . 198PRAXAIR SPECIALTY CERAMICS, INC. . 199PRAXAIR SURFACE TECHNOLOGIES, INC. 200PRAXAIR SURFACE TECHNOLOGIES COATING DIVISION. 200PRAXAIR TAFA . 200PRECISION COATINGS, INC. . 201PRIEST ELECTRIC . 201PROFESSIONAL CR

68、YOGENIC METALLURGY & COATINGS,LLC (PCMC). 202PROFESSIONAL METAL REFINISHING, INC. . 202PROGRESSIVE TECHNOLOGIES, INC. 202QQC/TURCHAN TECHNOLOGIES GROUP, INC. 202RAM COATING SERVICES LLC . 203RAM PRO LINE . 203SAINT GOBAIN GRAINS AND POWDERS . 203SANDVIK, INC. . 204SECO TOOLS, INC. . 204SERMATECH INT

69、ERNATIONAL INC. . 205SOLAR ATMOSPHERES INC. . 205SPECIALIZED CERAMIC AND POWDER COATINGS . 206SPIRE CORPORATION. 206ST. LOUIS METALIZING CO. 207Copyright BCC Research, Wellesley, MA USA, Web: xvAVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesTABLE OF CONTENTSSTARFIRE SYSTEMS INC. .

70、208STEEL PLANT EQUIPMENT CORP. . 208Steel Plant Equipment Corp. (Continued) . 209STELLITE COATINGS. 210STREETROD STUFF, INC. 210SULZER METCO (U.S.), INC. 211SYLCO INC. . 211SWAIN TECHNOLOGY INC. . 212TECH LINE COATINGS, INC. . 212TECHNETICS CORP. 212THIN AIR POWERSPORTS. 213TURBINE COMPONENTS SERVIC

71、ES. 213ULTRAMET . 214ULVAC TECHNOLOGIES INC. . 214VEECO INSTRUMENTS INC. 215WHITE ENGINEERING SURFACES CORPORATION . 215WHITE ENGINEERING SURFACES CORPORATION . 215Copyright BCC Research, Wellesley, MA USA, Web: xviAVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesLIST OF TABLESSUMMAR

72、Y TABLE NORTH AMERICAN MARKET FOR HIGH PERFORMANCE CERAMIC COATINGS BY TYPE OF COATINGTECHNOLOGY, THROUGH 2014 ($ MILLIONS) . 6TABLE 1 NORTH AMERICAN MARKET FOR HIGH PERFORMANCECERAMIC COATINGS, BY APPLICATION SEGMENT, THROUGH 2014($ MILLIONS) . 9TABLE 2 HIGHPERFORMANCE CERAMIC COATING MATERIALSAND

73、GENERAL APPLICATIONS . 12TABLE 3 REPRESENTATIVE FLAME AND PLASMA SPRAYEDMATERIALS MELTING OR SOFTENING TEMPERATURE USES . 13TABLE 4 PLASMA SPRAYED CERAMIC COATING PROPERTIES . 14TABLE 5 LEADING APPLICATIONS OF DEPOSITION BY INDUSTRY . 17TABLE 6 TYPICAL COATINGS AND APPLICATIONS . 19TABLE 7 CERAMIC M

74、ATERIALS USED IN THE POWDER FLAMEPROCESS . 23TABLE 8 PROPERTIES OF HVOF CARBIDE COATINGS . 35TABLE 9 COMPARISON OF THERMAL SPRAY PROCESSES . 38TABLE 10 DETONATION GUN APPLICATIONS IN THE GAS TURBINEENGINE. 41TABLE 11 THERMAL SPRAY COATINGS FOR FRPS . 52TABLE 12 RECENT DEVELOPMENTS IN THERMAL SPRAYCO

75、ATINGS . 53TABLE 13 LEADING U.S. COMPANIES PROVIDINGTHERMAL SPRAY COATING SERVICES FOR OEMPARTS. 57TABLE 14 NORTH AMERICAN CUSTOM/JOB SHOPSPROVIDING THERMALSPRAY COATING SERVICES. 57TABLE 15 LEADING U.S. COMPANIES PROVIDINGTHERMAL SPRAY COATING CONSUMABLES . 58TABLE 16 U.S. COMPANIES SUPPLYING CONSU

76、MABLESFOR NANOCERAMIC COATINGS . 59TABLE 17 U.S. MANUFACTURERS OF PLASMA SPRAY EQUIPMENT. 59TABLE 18 ACQUISITIONS, MERGERS AND OTHER BUSINESSRELATIONS IN THE THERMAL SPRAY INDUSTRY SINCE 1990 . 60TABLE 19 TOTAL NORTH AMERICAN EXPENDITURES ON THERMALSPRAY CERAMIC COATING OF AIRCRAFT GAS TURBINE PARTS

77、,THROUGH 2014 ($ MILLIONS) . 61TABLE 20 NORTH AMERICAN SHIPMENTS OFTURBOFAN, TURBOPROP, AND TURBOSHAFTENGINES, THROUGH 2014 (NUMBER OF ENGINES) . 61Copyright BCC Research, Wellesley, MA USA, Web: xviiAVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesLIST OF TABLESTABLE 21 COST OF AIRC

78、RAFT ENGINE COATING SERVICES,THROUGH 2014 ($ MILLIONS) . 63TABLE 22 NORTH AMERICAN AIRCRAFT GAS TURBINE ENGINEOVERHAUL MARKET THROUGH 2014 ($ MILLIONS) . 64TABLE 23 TOTAL NORTH AMERICAN EXPENDITURES ON THERMALSPRAY CERAMIC COATING OF LARGE LAND BASED TURBINEPARTS, THROUGH 2014 ($ MILLIONS) . 64TABLE

79、 24 COST OF NEW LARGE LANDBASED TURBINE COATINGSERVICES, THROUGH 2014 ($ MILLIONS) . 65TABLE 25 COST OF LARGE LANDBASED TURBINEREFURBISHMENT COATING SERVICES, THROUGH 2014 ($MILLIONS). 66TABLE 26 TOTAL NORTH AMERICAN EXPENDITURES ON THERMALSPRAY CERAMIC COATING OF WEAR RESISTANT PARTS ANDINDUSTRIAL

80、APPLICATIONS, THROUGH 2014 ($ MILLIONS) . 67TABLE 27 NORTH AMERICAN EXPENDITURES ON THERMAL SPRAYCERAMIC COATINGS IN AUTOMOTIVE AND DIESEL ENGINES,THROUGH 2014 ($ MILLIONS) . 69TABLE 28 TOTAL NORTH AMERICAN EXPENDITURES ON THERMALSPRAY CERAMIC COATINGS FOR MEDICAL APPLICATIONS,THROUGH 2014 ($ MILLIO

81、NS) . 70TABLE 29 NORTH AMERICAN CERAMIC THERMAL SPRAY COATINGMARKET, THROUGH 2014 ($ MILLIONS). 71TABLE 30 MARKET SHARE OF THERMAL SPRAY COATING SERVICEPROVIDERS (%) . 73TABLE 31 REPRESENTATIVE FILMS DEPOSITED BY PVD. 75TABLE 32 REPRESENTATIVE PVD SURFACE COATINGS FORABRASION AND CORROSION RESISTANT

82、 APPLICATIONS. 76TABLE 33 TYPES OF PHYSICAL VAPOR DEPOSITION PROCESSES . 78TABLE 34 BASIC SPUTTERING SOURCES AND PROCESSES . 83TABLE 35 COMPARISON OF MAGNETRON SPUTTERING METHODSFOR DEPOSITING SIO2 . 85TABLE 36 CERAMIC PVD APPLICATIONS . 92TABLE 37 PROPERTIES OF UNCOATED AND TIN COATED HSS . 94TABLE

83、 38 PROPERTIES AND APPLICATION OF VARIOUS BALZERSBALINIT THIN FILM WEARRESISTANT COATINGS . 96TABLE 39 RECENT DEVELOPMENTS IN PVD . 98TABLE 40 LEADING NORTH AMERICAN COMPANIESMANUFACTURING PVD SYSTEMS AND/OR PROVIDING SERVICES. 101TABLE 41 NORTH AMERICAN HIGH PERFORMANCE CERAMIC PVDCOATING MARKET, T

84、HROUGH 2014 ($ MILLIONS) . 102Copyright BCC Research, Wellesley, MA USA, Web: xviiiAVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesLIST OF TABLESTABLE 42 NORTH AMERICAN MARKET FOR CERAMIC PVD TOOLCOATINGS, THROUGH 2014 ($ MILLIONS) . 104TABLE 43 NORTH AMERICAN MARKET FOR CERAMIC COA

85、TINGSFOR AUTOMOTIVE, AEROSPACE AND WEAR RESISTANTAPPLICATIONS, THROUGH 2014 ($ MILLIONS) . 105TABLE 44 NORTH AMERICAN MARKET FOR CERAMIC PVD MEDICALDEVICE COATINGS, 20082014 ($ MILLIONS) . 106TABLE 45 MARKET SHARE OF CERAMCI PVD COATING SERVICEPROVIDERS, 2008 (%) . 106TABLE 46 CERAMICS DEPOSITED BY

86、CVD. 108TABLE 47 TYPICAL CERAMIC CVD COATINGS, PROCESS GASES ANDDEPOSITION TEMPERATURES. 110TABLE 48 CCVD MATERIALS, SUBSTRATES AND APLICAITONS . 117TABLE 49 KEY TECHNICAL ADVANTAGES OF THE CVD PROCESS . 118TABLE 50 KEY TECHNICAL DISADVANTAGES OF THE CVD PROCESS. 118TABLE 51 REPRESENTATIVE CVD CERAM

87、IC COATINGS . 119TABLE 52 OVERVIEW OF CURRENT/EMERGING CUTTING TOOL CVDAPPLICATIONS. 122TABLE 53 RECENT DEVELOPMENTS IN CERAMIC CVD COATING . 125TABLE 54 LEADING WORLDWIDE MANUFACTURERS OF CVDEQUIPMENT . 126TABLE 55 LEADING WORLDWIDE CVD SERVICE PROVIDERS . 127TABLE 56 NORTH AMERICAN CERAMIC CVD COA

88、TING SERVICEMARKETS BY APPLICATION, THROUGH 2014 ($ MILLIONS). 129TABLE 57 NORTH AMERICAN MARKET FOR CERAMIC CVD TOOLINSERT COATINGS, THROUGH 2014 ($ MILLIONS) . 131TABLE 58 NORTH AMERICAN MARKET FOR CERAMIC CVD WEARRESISTANT AND OTHER INDUSTRIALCOATING APPLICATIONS,THROUGH 2014 ($ MILLIONS) . 132TA

89、BLE 59 NORTH AMERICAN MARKET FOR CERAMIC CVDAUTOMOTIVE COMPONENT COATINGS, THROUGH 2014 ($MILLIONS). 134TABLE 60 NORTH AMERICAN MARKET FOR CERAMICCVD AEROSPACE COATINGS, THROUGH 2014 ($MILLIONS). 135TABLE 61 NORTH AMERICAN MARKET FOR CERAMIC CVD MEDICALDEVICE COATINGS, THROUGH 2014 ($ MILLIONS). 136

90、TABLE 62 MARKET SHARE OF CERAMIC CVD COATING SERVICEPROVIDERS (%) . 137TABLE 63 TEMPERATURE DROP USING COATED HEADERS IN AUTOENGINES (F) . 141Copyright BCC Research, Wellesley, MA USA, Web: xixAVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesLIST OF TABLESTABLE 64 APPLICATIONS OF SOL

91、 GEL FILMS AND COATINGS . 147TABLE 65 NORTH AMERICAN COMPANIES PROVIDING CERAMICCOATING SERVICES USING SPRAYING, DIPPING, SOL GEL, LASERAND IONIC BEAM TECHNIQUES. 157TABLE 66 NORTH AMERICAN CERAMIC CVD COATING OTHERSERVICE MARKETS BY APPLICATION, THROUGH 2014 ($MILLIONS). 161Copyright BCC Research,

92、Wellesley, MA USA, Web: xxAVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesLIST OF FIGURESSUMMARY FIGURE MARKET SHARE OF NORTH AMERICAN HIGH PERFORMANCE CERAMIC COATING TECHNOLOGIES, 2008 2014 (%TOTAL MARKET). 7FIGURE 1 SHARE OF NORTH AMERICAN HIGH PERFORMANCECERAMIC COATING SERVICE

93、MARKET SEGMENTS, 2008 2014. 10FIGURE 2 PLASMA SPRAY COATING TECHNIQUE . 27.FIGURE 3 SCHEMATIC OF HVOF. 33FIGURE 4 SHARE OF NORTH AMERICAN CERAMIC THERMAL SPRAYCOATING SERVICE MARKET SUB SEGMENTS, 20082014. 72FIGURE 5 A COMPARISON OF THE TRS OF UNCOATED AND COATEDCARBIDE AS MEASURED BY THE THREE POIN

94、T BEND TEST ON0.2 X 0.2 X 0.75 INCH SPECIMENS. 95FIGURE 6 SHARE OF NORTH AMERICAN CERAMIC THERMAL SPRAYCOATING SERVICE MARKET SUBSEGMENTS, 2008 2014 (% OFTOTAL THERMAL SPRAY MARKET). 103FIGURE 7 SUMMARY OF CARBIDE METALCUTTING GRADEDEVELOPMENT . 121FIGURE 8 SHARE OF NORTH AMERICAN CERAMIC CVD COATIN

95、GSERVICE MARKET SEGMENTS, 20082014 (% OF TOTAL CVDCOATING MARKET). 130FIGURE 9 SHARE OF NORTH AMERICAN CERAMIC COATINGSMARKET USING SPRAYING/DIPPING, SOL GEL, MICRO OXIDATIONAND LASERASSISTED TECHNIQUES BY APPLICATION, 2008 2014(%) . 162Copyright BCC Research, Wellesley, MA USA, Web: 1AVM015EHighPer

96、formance Ceramic Coatings: Markets and TechnologiesCHAPTER ONE:INTRODUCTIONFor more than 20 years, BCC Research has been tracking developments in thehighperformance ceramic coatings market. Since the last edition of this report waspublished in 2007, significant changes have taken place in the cerami

97、c coatingservice industry. In view of these changes, BCC decided that there is now a need toupdate the previous editions findings and conclusions.STUDY GOALS AND OBJECTIVESThis report is intended to:Provide an industry overview of ceramic coatings delivered by thermalspray, physical vapor deposition

98、 (PVD), chemical vapor deposition (CVD)and other techniques including spraying/dipping, sol gel, microoxidation,packed diffusion, ionic beam surface treatment and laser assistedtechniquesDetermine the current size and future growth of the North Americanmarkets for ceramic thermal spray, PVD, CVD and

99、 other coatings servicesProvide a technology overview, including material types, properties andapplications for ceramic coatingsAnalyze domestic competition among companies within each of theceramic coating service segmentsProfile all North American equipment manufacturers, service providersand supp

100、liers of consumables among ceramic thermal spray, PVD, CVDand other coating techniquesIdentify the users of ceramic coating services.REASONS FOR DOING THE STUDYCeramic coatings constitute a large family of materials with quite diversecompositions and properties. They include compositions based on al

101、umina,aluminamagnesia, chromia, hafnia, silica, silicon carbide, titania and zirconia.Ceramic coatings are generally applied to metal or metallic alloy components or toceramic componentsHighperformance ceramic coatings are a special class of ceramics in their form andthe preparation techniques requi

102、red. However, their uses are diverse, and theyexploit the wide range of unique and desirable properties of various bulk ceramics.Copyright BCC Research, Wellesley, MA USA, Web: 2AVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesCeramic coatings are generally used for wear (or erosion)

103、, corrosion and hightemperatureresistant applications. All ceramic coatings deliver some level ofperformance in each of the three major areas listed above.The availability and commercialization of highperformance coatings have alreadychanged the internal specification patterns of certain industries,

104、 such as cuttingtool inserts. The useful life of coated inserts is many times the life of uncoatedinserts. This, in turn, has reduced the cost of cutting tool inserts, and at the sametime has increased productivity. Similarly, ceramiccoated components for aircraftturbine engines resulted in building

105、 large aircraft. Now, auto enthusiasts arecoating certain auto engine components to improve auto engine performance. Also,ceramic coatings have made it possible for certain large machine components to berepaired in situ.INTENDED AUDIENCEThis new BCC study provides an indepth analysis of the material

106、s, applications,economics, current markets and trends, and the players. Forecasts are provided foreach major market segment through 2014. Indepth analyses have been providedfor the North American ceramic coatings industry structure, providing detailedinformation on major players and markets for each

107、 application.Through this report, BCC hopes to provide a better understanding of the NorthAmerican ceramics coatings industry. This study provides the most uptodateinformation we have gathered on the highperformance ceramic coatings marketsegments. The report further describes various kinds of ceram

108、ic depositiontechnologies, new developments and recent patents, advantages and limitations ofcurrently used techniques, and profiles of all North American players involved inthis industry.This study is directed to the various strata of companies and institutions interestedin the markets and new deve

109、lopments in this growing field. They are:Companies involved in developing, manufacturing and supplyingadvanced materialsCompanies involved in the development and manufacture of highperformance metallic and ceramic componentsSuppliers of advanced ceramic powders and componentsManufacturers and suppli

110、ers of thermal spray, PVD, CVD and ionic beamand laser beam coating equipmentProducers of vacuum equipmentSuppliers of coating consumablesProviders of coating servicesCopyright BCC Research, Wellesley, MA USA, Web: 3AVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesOEM suppliersGovern

111、ment agencies involved in advanced materials researchProducers of aircraft engines and/or engine componentsCompanies doing repair and refurbishing of aircraft enginesProducers of automotive and diesel enginesJob shops providing coating services to racing car and other auto enginesProducers of cuttin

112、g tools, bearings, textile guides and pulleys, extrusionand drawing dies, nozzles, mechanical seals and valves, and other wearresistant partsCompanies involved in the development and use of ceramics and highperformance ceramic coatings for aerospace and military applicationsVenture capital companies

113、 and financial institutions interested in new andattractive investments.SCOPE OF REPORTThis BCC study has been conducted with a global perspective in terms of materialsand their applications. Market projections have been conducted for North America.All market table values are in 2008 U.S. dollars.Th

114、e report provides business planners and managers with an improvedunderstanding of the direction and impact of the highperformance ceramic coatingtechnologies, and how markets will be affected and new opportunities created.The report contains:An indepth analysis of the technologies used for highperfo

115、rmanceceramic coatings.An overview of materials for highperformance ceramic coatings and theirproperties.New developments and recent patents in highperformance ceramicthermal spray, PVD, CVD and other coating techniques.Current and potential applications for highperformance ceramiccoatings.Current a

116、nd future market projections for ceramic coatings in all the majorapplications.Profiles of current industry players including suppliers of equipment,consumables, coating service providers and users.A review of the economic/market opportunities for current industryparticipants and new entrants.BCC fe

117、els, therefore, that the qualitative and quantitative judgments embodied inthis report are a valuable contribution to the current knowledge of highperformance ceramic coatings.Copyright BCC Research, Wellesley, MA USA, Web: 4AVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesMETHODOLOG

118、Y AND INFORMATION SOURCESThis report is an updated version of a report originally published in 2004 andsubsequently updated in 2007. Both primary and secondary researchmethodologies were using in preparing this report. Information for the original andupdated reports were collected through extensive

119、industry contacts with peopleactive in the research, development, production and use of highperformanceceramic coatings, from government and academic sources and by reference totechnical literature. Several industry experts were also interviewed for this study.In addition, most of the coating servic

120、e providers and end users were contacted toevaluate current and future demands for these coatings.More than 200 industry contacts assisted BCC in identifying and updatingtechnologies and applications. In addition to utilizing its in-house database onceramic coatings, BCC conducted extensive Web sear

121、ches to gather and analyze allpertinent information related to this study. Major technical and trade publicationsand conference proceedings in ceramic coatings were also used for this study.AUTHOR S CREDENTIALSThis report is an update of an earlier (2004) report prepared by Dr. ThomasAbraham. Dr. Ab

122、raham was formerly Vice President and Director of the AdvancedMaterials Group of BCC. Dr. Abraham has extensive experience in the field ofadvanced materials, including advanced ceramics, synthetic diamonds and diamondfilms, magnetic materials, highperformance coatings, and superconductors.The analys

123、t responsible for updating the report is Andrew McWilliams, a partner inthe Bostonbased international technology and marketing consulting firm, 43rdParallel LLC. Mr. McWilliams is the author or coauthor of numerous other BCCstudies, including studies in related fields such as AVM025F Diamond, Diamon

124、dLike and CBN Films and Coating Products; NAN015E Advanced Ceramics andNano Ceramic Powders; NAN021D Nanocomposites, Nanoparticles, Nanoclays, andNanotubes; NAN040A Nanomaterials Markets by Type; and AVM008B SyntheticGems and Minerals.RELATED BCC REPORTSReaders of this report may also find the follo

125、wing BCC Research reports of interest:AVM025FAVM008BDiamond, DiamondLike and CBN Films and CoatingProductsSynthetic Gems and MineralsCopyright BCC Research, Wellesley, MA USA, Web: 5AVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesAVM009DAVM011CAVM016EAVM028DAVM033AAVM038CAVM049BAVM0

126、54AHLC010DNAN015EPLS039DAdvanced Glasses and Glass Ceramics: Materials,Processing, New DevelopmentsTechnical and Advanced Structural CeramicsSol Gel Processing of Ceramics and GlassThe Friction Products and Materials MarketAbrasive Products: Materials, Applications and MarketsAdvanced Structural Car

127、bon Products: Fibers, Foams andCompositesMetal and Ceramic Injection MoldingBioactive Glasses, Ceramics, Composites, Other AdvancedMaterialsBiocompatible Materials for the Human BodyAdvanced Ceramics and Nano Ceramic PowdersHighPerformance FilmsBCC ONLINE SERVICESBCC offers an online information ret

128、rieval service. BCCs home page, located , enables readers to:Examine BCCs complete catalog of Market Research Reports and placedirect ordersSubscribe to any of BCCs many industry newslettersRead announcements of recently published reports and newly launchednewslettersRegister for BCCs well-known con

129、ferencesRequest additional information on any BCC productTake advantage of special offersDISCLAIMERThe information developed in this report is intended to be as reliable as possible atthe time of publication and of a professional nature. This information does notconstitute managerial, legal, or acco

130、unting advice; nor should it serve as a corporatepolicy guide, laboratory manual, or an endorsement of any product, as much of theinformation is speculative in nature. The author assumes no responsibility for anyloss or damage that might result from reliance on the reported information or itsuse.Cop

131、yright BCC Research, Wellesley, MA USA, Web: 16AVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesCHAPTER TWO:EXECUTIVE SUMMARYSurface modification using ceramic coatings has achieved an important place in theindustrial environment over the past several decades. Highperformance ceramic

132、coatings constitute a mature but still expanding industry with a broad list ofcurrent and potential applications, continuously emerging coating techniques and agrowing list of materials compositions.The North American market for highperformance ceramic coatings was worth anestimated $1.42 billion in

133、 2008. This figure is expected to fall slightly to $1.4 billionfor 2009, but should rise to more than $2.0 billion by 2014 at a projected 5yearcompound annual growth rate (CAGR) of 7.6%.SUMMARY TABLENORTH AMERICAN MARKET FOR HIGH PERFORMANCE CERAMICCOATINGS BY TYPE OF COATING TECHNOLOGY, THROUGH 201

134、4($ MILLIONS)CoatingCAGR%TechnologyThermal sprayCVDPVDOther *Total2008942.6213.0181.078.41,415.02009953.3183.4186.971.91,395.520142, 4.22009 2014*Includes spraying/dipping, sol gel, microoxidation and laser assisted techniques.Source: BCC ResearchThermal spray coatings dominate the market, with abou

135、t 67% of total sales in 2008,projected to increase to 70% by 2014. CVD accounted for the secondlargest shareof the market in 2008, (i.e., 15%, but is expected to drop into third place behind PVDwith 11% of the market in 2014). The share of PVD, meanwhile, is projected toremain relatively steady at a

136、round 13% from 2008 through 2014. Other coatingtechnologies (e.g., spraying/dipping, sol gel, microoxidation and laserassistedtechniques) should make small gains in market share, (i.e., from 5.5% in 2008 to5.8% in 2014).Copyright BCC Research, Wellesley, MA USA, Web: 07AVM015EHighPerformance Ceramic

137、 Coatings: Markets and TechnologiesSUMMARY FIGUREMARKET SHARE OF NORTH AMERICAN HIGH PERFORMANCECERAMIC COATING TECHNOLOGIES, 2008 2014(% TOTAL MARKET)706050403020100200820092014Thermal sprayCVDPVDOther*Includesspraying/dipping, sol gel, microoxidation and laser assisted techniques.LEGEND(%)Technolo

138、gyThermal sprayCVDPVDOther*Total200866.6015.1012.805.50100.0200968.3013.1013.405.20100.020142080100.0Source: BCC ResearchCopyright BCC Research, Wellesley, MA USA, Web: 8AVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesCHAPTER THREE:INDUSTRY OVERVIEWThe structure of the ceramic coati

139、ng industry from raw materials to enduseproducts includes suppliers of ceramic coating consumables, suppliers of coatingsystems, job shops providing coating services, and end users including those withinhouse coating facilities.INDUSTRY STRUCTUREIn North America, there are more than a dozen supplier

140、s of coating consumables;more than a dozen suppliers of thermal spray, PVD and CVD systems; more than100 job shops providing coating services; and about 25 companies and organizationswith inhouse coating facilities, including major airlines and militaryestablishments. In addition, a large number of

141、companies and organizations, bothgovernment and private, are involved in research and development (R&D) andtesting of new ceramic coatings.A few of the companies in the ceramic coating industry are fully integrated, (i.e.,they manufacture and supply coating consumables as well as provide coatingserv

142、ices). Most of the suppliers of ceramic coating consumables also supplyconsumables for metal and alloy coatings. Job shops providing coating services alsoprovide other coatings such as metal and alloy.Many of the end users, particularly companies manufacturing aircraft engines andcarbide tool insert

143、s, have their own inhouse coating facilities. For example, all themajor coated carbide tool manufacturers have their own inhouse coating facilities,and most of the major airlines also have their own coating facilities for the overhauland maintenance of their engines. The Air Force, Navy, and Marines

144、 overhaul theirengines inhouse. Many of the operators of land based turbine engines also havetheir inhouse coating facilities.The highperformance ceramic coating service industry runs the gamut fromcompanies with sales in the tens of millions of dollars to small job shops. Due to thedecline in the a

145、erospace industry, some smaller companies have downsized orstruggled to stay in business, or have gone out of business completely. During thisperiod, several acquisitions and mergers occurred. In addition, some companiessold their coating service business as a separate entity. However, by the late 1

146、990s,there was increased activity in high performance ceramic coatings using thermalspray, especially in aircraft engines and automotive applications. These increasedactivities have resulted in more licensing and development/marketing activities.BCC identified over a dozen such business relationship

147、s in recent years.Copyright BCC Research, Wellesley, MA USA, Web: 9AVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesTECHNICAL AND BUSINESS ISSUESThe technique used to deposit a ceramic coating greatly influences itsmicrostructure and performance. Therefore, depending on the applicati

148、ons, thecoating technique has to be selected to achieve optimum properties for the coatedcomponents.Although there are several major suppliers of coating services, there are asignificantly larger number of smaller companies, especially in the thermal sprayarea, due to the ease of entry into this bus

149、iness as a result of relatively lower capitalcosts. The thermal spray market is very sensitive to market forces. In the early1990s, a downturn in military demand led to the closure of many smaller shops.However, with new enthusiasm among the owners of racing cars and even some carowners to improve a

150、uto engine performance, new coating service companies havebeen established to provide such services.NORTH AMERICAN MARKETSThe overall North American market for high performance ceramic coatings isexpected to decline from $1.42 billion in 2008 to less than $1.4 billion in 2009, thenincrease to more t

151、han $2.0 billion by 2014, representing a 5year CAGR of 7.6%.Aircraft engines and other aerospace applications account for, by far, the largestshare of the market, as shown below.TABLE 1NORTH AMERICAN MARKET FOR HIGH PERFORMANCE CERAMICCOATINGS, BY APPLICATION SEGMENT, THROUGH 2014($ MILLIONS)CAGR %A

152、pplication Segment2008200920142009 2014Aircraft engines and aerospace713.1727.61,.53Wear parts and other industrialToolsAutomotiveMedicalPower generationHeat exchangers and high temperature useOther276.0202.083.462.055.514.09.0261.5179.075.870.957.714.09.03 .1.4.7.47.512.Total1,415.01,395.52,.2.6Sou

153、rce: BCC ResearchCopyright BCC Research, Wellesley, MA USA, Web: 10AVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesAircraft engines and other aerospace applications accounted for more than half ofthe market, (i.e., 50.4% in 2008, increasing to 53.9% by 2014). Wear parts and otherind

154、ustrial applications make up the secondlargest segment (19.5% in 2008,declining to 18.3% by 2014), followed by cutting tools (14.3% in 2008 vs. 10.2% in2014).FIGURE 1SHARE OF NORTH AMERICAN HIGH PERFORMANCE CERAMICCOATING SERVICE MARKET SEGMENTS, 2008 2014(%)6050403020100200820092014Aircraft engines

155、 and aerospaceToolsHeat exchangers and high temperature usePower generationWear parts and other industrialMedicalAutomotiveOtherLEGENDMarket SegmentAircraft engines and aerospaceWear parts and other industrialToolsMedicalHeat exchangers and high temperature useAutomotivePower generationOtherTotal200

156、850.4019.5014.304.401.005.903.900.60100.0200952.1018.7012.805.101.005.404.100.60100.02014100.0Note: Percentages may not appear to add exactly to 100 due to roundingSource: BCC ResearchCopyright BCC Research, Wellesley, MA USA, Web: 11AVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesI

157、NTERNATIONAL COMPETITIONThe U.S. is ahead of Japan and Europe in ceramic coating services. One majorreason for this leadership is this countrys large established industries, such asaircraft engines and aerospace, as well as the military. These industries needhigher performance components, which prov

158、ide incentives for service providers toresearch, develop, and produce these components.There is no direct competition from foreign companies for which the U.S. coatingservice providers must contend, although some foreign firms have set up shop inNorth America. Rarely does a company send out its part

159、s to a foreign country forcoatings and then bring them back. In the 1990s, some North American airlines didset up engine refurbishing shops outside North America, however, conditions havechanged and the current tendency is to keep these shops in North America itself.Copyright BCC Research, Wellesley

160、, MA USA, Web: 12AVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesCHAPTER FOUR:TECHNOLOGY OVERVIEWHighperformance ceramic coatings are generally used for wear (or erosion),corrosion and hightemperatureresistant applications. All ceramic coatingsdeliver some level of performance in ea

161、ch of the three major areas listed above. Forexample, some coatings may serve primarily as thermal barriers, while alsoproviding abrasion resistance. In other cases, the coatings may be used at elevatedtemperatures. However, they may also provide resistance to corrosiveenvironments.The promise of pe

162、rformance improvements is the main force driving the continueddevelopment and commercialization of highperformance ceramic coatings. Thesecoatings are generally applied to cast iron, steel, superalloys, titanium alloys,tungsten carbides, carbon/carbon composites and even ceramics. Use of ceramiccoat

163、ings enables metals to be used for several applications for which they wouldotherwise be unsuitable.MATERIAL TYPES AND PROPERTIESOxides and carbides are the materials most commonly used for high performanceceramic coatings. Oxides include Al2O3, ZrO2, Cr2O3, SiO2, and TiO2, while carbidesinclude SiC

164、, B4C, Cr3C2, Mo2C, TiC, and WC. Among oxides, zirconia has beenfinding new applications, however changes occur in the crystalline structure of pureZrO2 at 1,000 C and this causes cracking. To prevent this, CaO, Y2O3 and MgO areadded to ZrO2 for stabilization. The next table lists the various cerami

165、c coatingmaterials for highperformance applications.TABLE 2HIGH PERFORMANCE CERAMIC COATING MATERIALSAND GENERAL APPLICATIONSUseWear reductionFriction reductionTypical Ceramic MaterialAl2O3, B4C, Cr3C2, CrB2, CrSi2, Cr3Si2, DLC*, Mo2C, MoSi2, SiC, GeC, TiB2,TiC, TiN, AlN, WCMoS2, BN, BaF2/Ca2Corrosi

166、on resistance Cr2O3, Al2O3, Si3N4, AlN, SiO2, ZrO2, TiO2Thermal protectionCa2Si4, MgAl2O4, MgO, ZrO2 (Mg or Ca stabilized)DLC*=Diamondlike carbonSource: BCC ResearchCopyright BCC Research, Wellesley, MA USA, Web: iPPP,OP,OP,OPPP,OPPP,O13AVM015EHighPerformance Ceramic Coatings: Markets and Technologi

167、esAmong these ceramic coatings, thermal spray coatings (flame, plasmasprayed, andother coatings) constitute the majority. Table 3 lists flame and plasmasprayedmaterials, their melting and softening temperatures, and uses. Properties ofplasmasprayed coatings are shown in Table 4.TABLE 3REPRESENTATIVE

168、 FLAME AND PLASMA SPRAYED MATERIALS MELTING OR SOFTENING TEMPERATURE USESMelting orSofteningMethod ofTemperatureMaterialAluminaApplicationP,OMF3,700UsesHeat and abrasion resistance, flamesprayed shapesBtittPO3 010Diele t itieio t Al O3,435ingredient in cermetsColumbium (niobium)4,379Hard (over Rc 60

169、) coatings, selfbondingColumbium (niobium)carbideHafnium oxide6,330Hard, wearresistant coatingsHard, dense, high Barns numberMagnesia alumina5,030thermal barrierHard, dense abrasionresistant coatings.spinel3,875Resists attack by molten glass.Magnesium zirconate3,830Thermal barriers, molten metalresi

170、stance, coating graphiteMiscellaneous glassesTantalumTantalum carbideP,O800 to 2,0005,4257,0208,730Dielectrics, sealsCatalytic uses, selfbondingHard, wearresistant coatingsTitanium oxide3,490Abrasion resistance where low porosity isneeded, and for blends with otherrefractoriesTungstenTungstencarbide

171、crystallineTungsten carbide +cobalt6,1705,0352,715Hightemperature abrasion resistanceHightemperature abrasion resistanceUnfused wearresistance, fusedblendedwith Ni and Co alloys for abrasionresistance(continued)Copyright BCC Research, Wellesley, MA USA, Web: P,O14AVM015EHighPerformance Ceramic Coati

172、ngs: Markets and TechnologiesTABLE 3(CONTINUED)Melting orSofteningMethod ofTemperatureMaterialZirconium oxideApplicationP,OMF4,700Thermal barriersUsesZirconium oxide(hafniumfree)4,700Hard, low Barns number thermal barrierZirconium silicateP,O4,390Thermal barriers*P = Plasma flame equipment; O = Oxya

173、cetylene equipmentSource: Encyclopedia/Handbook of Materials, Parts and Finishes, H.R. Clauser, ASM Intl.TABLE 4PLASMA SPRAYED CERAMIC COATING PROPERTIESAluminumOxideChromeAluminumOxideTitaniumDioxideChromeOxideOxideSilicaMagnesiumOxideZirconiumOxideHardness (Rc)606370723145Surface finish (rms)As sp

174、rayedGroundGround andlappedSalt waterHydrochloric acidSodium phosphate100150122048GoodGoodGood200300102048GoodFairUnfavorable1502501525610GoodGoodGood2002501520610GoodGoodGood2504001020610FairUnfavorableGood2002501520812GoodFairGoodGeneral resistancerankThermal shockresistanceThermal barrierquality3

175、Very GoodVery Good4FairFair2FairN/A1GoodN/A6ExcellentExcellent5ExcellentExcellent(continued)Copyright BCC Research, Wellesley, MA USA, Web: 15AVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesTABLE 4(CONTINUED)AluminumOxideChromeAluminumOxideTitaniumDioxideChromeOxideOxideSilicaMagnes

176、iumOxideZirconiumOxideSpecial propertiesLeastLow costGoodBest wearNot wettedBest thermalexpensiveWhite colorHighdielectricstrengthGood finish abrasionGood wear resistanceGoodcorrosionresistanceresistanceImpactresistanceby moltenmetalHigh temp.wearbarrierGoodoxidationresistanceSource: Heany Industrie

177、s, Inc., Scottsville, NYNanostructured ceramic feedstocks are used in a growing number of applications,such as the alumina/titania nanoceramic thermal spray coatings used in variousmarine settings. Other ceramic nanocomposite coating materials that are in theearly stages of commercialization or unde

178、r development and expected to becomeavailable in the near future include coatings based on ceramics such as tungstencarbide, chrome oxide and yttriastabilized zirconia.COATING TECHNIQUESCeramic coatings are generally applied using spraying and dipping, chemical vapordeposition (CVD), physical vapor

179、deposition (PVD), thermal spray (flame or plasma)techniques and newer methods such as sol gel, laserassisted and ion beamassisted technologies. Thermal spray coatings can be accomplished by flame orplasmaspray techniques to produce thermal barrier or hightemperature coatings.Another technique uses a

180、 detonation gun (Dgun) to produce dense and smoothcoatings.Thermal spray coating involves the use of a torch to heat a material, in powder orwire form, to a molten or nearmolten state, and the use of a gas to propel thematerial to the target substrate, creating a completely new surface. The coatingm

181、aterial may be a single element, alloy or compound with unique physicalproperties that are, in most cases, achievable only through the thermal sprayprocess.Thermal barrier or hightemperature coatings can be applied by simple brushing ordipping, spraying, flow coating, combustion flame spraying, plas

182、maarc flamespraying, detonation gun spraying, fluidizedbed deposition, etc. Selection ofcoating methods depends on the following factors:Copyright BCC Research, Wellesley, MA USA, Web: 16AVM015EHighPerformance Ceramic Coatings: Markets and Technologiessubstrate materialcoating materialsize and shape

183、 of the part to be coatedcostservice conditionsMethods for depositing films and coatings vary from chemical vapor deposition(CVD), where a reaction of the vaporphase species with the sample surfaceproduces a coating, to physical vapor deposition (PVD), in which a vapor flux iscreated by a physical p

184、rocess such as evaporation or sputtering, to thermal sprayingwhere traditionally, an electric arc, flame or plasma is used to melt a powder orwire source.COATING TECHNIQUES (CONTINUED)In the ion implantation process, ions are created in a source, accelerated at mediumor high voltages, and implanted

185、into the surface. Ion beamassisted deposition(IBAD) combines a physical deposition source of vapor atoms with a source toproduce energetic ions that bombard the growing film, and frequently includes asource of reactive gas. IBAD uses independent sources for ions and vapor atomsand provides good cont

186、rol of process variables.The selection of a deposition process depends on the objectives of a particularapplication and the properties that must be imparted. In this study, we review thebasic deposition processes and discuss evolving technologies that are beingdeveloped to handle the requirements of

187、 new products and advanced materials.Key deposition technologies include:Thermal sprayo Combustion thermal sprayo Arc wire thermal sprayo Plasma thermal sprayo HVOF thermal sprayo Jet Kote processo Detonation gun processPhysical vapor depositiono Evaporationo SputteringChemical vapor depositiono Low

188、pressureo Atmospheric pressureo PlasmaassistedCopyright BCC Research, Wellesley, MA USA, Web: Tooling17AVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesMetalorganico Laser assistedPulsed laser depositionQQC processCementationMicrodischarge depositionSol gel processingIon assisted dep

189、ositiono Ion beamassisted deposition (IBAD)o Ionic beam surface treatment (IBEST)Spraying and dippingGENERAL APPLICATIONSThere are many applications for the deposition of materials and coatings. Thistechnology, in conjunction with other processes, has made possible thesophistication and expansion of

190、 many industries including microelectronics andmedical devices.The major industry groups and some of the leading applications of depositiontechnologies are listed in the table below.TABLE 5LEADING APPLICATIONS OF DEPOSITION BY INDUSTRYIndustryMicroelectronicsInformationAutomotive/aerospaceLeading Ap

191、plicationsDielectric, conductive and diffusion layers for semiconductors, components,and flat panel displaysConducti e and protecti e coatings for consumer and computer tapes and discsCorrosion and wear resistance for various autosAircraft partsAbrasion and wearresistant coatings for cutting tools,

192、turning tools andother instruments(continued)Copyright BCC Research, Wellesley, MA USA, Web: Medical18AVM015EIndustryIndustrialHighPerformance Ceramic Coatings: Markets and TechnologiesTABLE 5(CONTINUED)Leading ApplicationsThromboresistant and anticorrosive layers for various medical devices andsurg

193、ical implantsCorrosion and wearresistant coatings for a variety of industrial, householdand consumer productsSource: BCC ResearchCeramic coating technology is expanding with a wide array of current and potentialapplications, continuously emerging coating techniques, and an evergrowing list ofmateria

194、l compositions. Ceramic coatings are being used effectively in variouselevated temperature applications, providing energy savings, extending service lifeof components and increasing production. These coatings also are used for wearand corrosionresistance applications.Components with ceramic coatings

195、 are attractive especially because of their wearresistance at elevated temperatures. If low friction is needed in addition to wearresistance, some types of softer materials are of interest.Ceramic coatings can be used in a variety of applications. Among typical ceramicand metal coating applications

196、are mechanical and/or thermal protection for enginecomponents, enhancement of tribological properties for wearresistant parts;thermal and mechanical protection for heat exchangers; and hard, chemicallyresistant and aesthetic coatings for medical applications. Some of the applicationscurrently used o

197、r being tested include gas turbines for generating electricity; dieselengine parts such as plugs, supercharger blades, combustion heads, rocker armsand camshafts; boiler parts including burner guards, air nozzles, tubes, etc.Ceramic coatings are also being tested for high temperature gascooled react

198、ors(HTGR). Table 6 lists applications and coatings used. Industries where ceramiccoatings have applications are:Thermal Insulationo Jet engines: fan blades, compressor blades, turbine blades, andsealso Automotive engines: combustion heads, valves, pistonso Large turbine engines: combustion, afterbur

199、nerAbrasion Resistanceo Petroleum Industry: pump shafts and plungers, turbine rotorshafts, seals, compressor rodsCopyright BCC Research, Wellesley, MA USA, Web: 19AVM015EHighPerformance Ceramic Coatings: Markets and Technologieso Plastics Industry: extruder barrels and screws, cutter shafts,extruder

200、 die plateso Textile Industry: draw rolls, finish applicator rolls, takeup rolls,heater plates, thread guideso Cutting tool industry: coated toolsHigh Temperature/Corrosion Resistanto Centrifugal compressors: rotor wheelso Large steam turbines: turbine rotoro Chemical process industry: heat exchange

201、rso Metallurgical process industry: ceramic metal coatings for furnacecomponents, refractory coatingsTABLE 6TYPICAL COATINGS AND APPLICATIONSUndercoat/%Top Coat/%Remarks1. Molten aluminum2. + Abrasion3. Molten steel4. + Abrasion5 M lt20. Abrasive coat21. Abrasive coat22. Abrasive coat23. AbradableNi

202、CrAlFeSiBo+WcCoNiCrAlFeSiBo+WcCoNiCAl2O3 TiO2 (83/17)MgOMgO ZrO2 (20/80)MgO ZrO2 (20/80)M O ZrO (35/65)WCCoCr3C2+NiCr (75/25)Al2O3+TiO2 (Th/L)NiCrAl (70/20/10)1,400 F1,400 F2,800 F2,800 F2 000 F1,000 F1,500 F1,600 F1,600 F(continued)Copyright BCC Research, Wellesley, MA USA, Web: 20AVM015EHighPerfor

203、mance Ceramic Coatings: Markets and TechnologiesTABLE 6(CONTINUED)Undercoat/%Top Coat/%Remarks24. Oxidation25. Oxidation26. Steel slag27. Steel slagNiAlFeSiBoNiCr (75/25)NiCrAl (70/20/10)Al2O3/MgOZrSiO4/MgO1,800 F1,600 F2,600 F2,600 FSource: Jorge A. Morando, Plasmafusion, Inc., Grosse Ile, MICompon

204、ents with ceramic coatings are attractive, especially because of their wearresistance at elevated temperatures. If low friction is needed in addition to wearresistance, some types of softer materials are of interest.Hightemperature, corrosionresistant applications involve a complex field ofchemical

205、reactions and protective mechanisms requiring protective coatings. Theprotective mechanism often calls for production of a dense, adherent, diffusionresistant oxide film by in situ oxidation as, for example, chromia, and alumina onhightemperature super alloys and silica on silicon carbide. This requ

206、ires that thebase material, alloy or ceramic have a selfpassivating composition. More effortsare now directed toward developing pinholefree coatings with sufficient adherenceto use as corrosion protection mechanisms.Thermalprotection coatings, consisting of a thin layer of ceramic applied over ameta

207、llic bond coat, are used in some gas turbine components, such as combustionchambers. One factor limiting their use is bond coat oxidation and stressdevelopment.Copyright BCC Research, Wellesley, MA USA, Web: 21AVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesCHAPTER FIVE:THERMAL SPRA

208、YTHERMAL SPRAY TECHNIQUESThermal spray is a generic term to describe coating processes that use a heat sourceto melt or plasticize a powder or wire and propel the molten particles onto acarefully prepared surface. Thermal spray coatings are a highly costeffective andstraightforward method for adding

209、 superior properties and performance qualities toa given engineering surface. The variety of products and coatings that can beenhanced by thermal spray is virtually limitless. The coatings can be metallic,ceramic, plastic or any desired combination to meet a range of physical criteria.A wide variety

210、 of materials from ordinary to exotic metals and ceramics can beapplied by thermal spray. The three heat sources most widely used are electric arc,combustion, and plasma. Each has its unique advantages depending on theapplication.Thermal spray coatings are used to extend product life, increase perfo

211、rmance andreduce production and maintenance costs. These coatings are most typically usedfor clearance control, such as abradable or knifeedge seals; as thermal barriers forheat protection; and in a variety of applications for wear reduction or dimensionalrestoration of critical parts, such as jet e

212、ngine and landbased gas turbinecomponents. A wide variety of thermal spray processes are available, includingelectric arc, plasma, highvelocity oxyfuel flame, and detonation.COMBUSTION WIRE THERMAL SPRAY PROCESSThe combustion wire thermal spray process, formerly known as the metalizing,flame sprayin

213、g and metal spraying process, was invented in 1910 by Max UlrichSchoop in Switzerland. Portable and reliable, wire flame spray is the earliestthermal spray process to be developed that is still in use today. A low initialexpenditure makes this an ideal process for entrylevel thermal spray coating.Ea

214、sily transported for onsite applications, wire flame spray is a favorite forinfrastructure corrosion applications, such as bridgework.The process basically involves the spraying of molten metal onto a surface toprovide a coating. Material in wire form is melted in a flame (oxyacetylene flame isthe m

215、ost common) and atomized using compressed air to form a fine spray. Whenthe spray contacts the prepared surface of a substrate material, the fine moltendroplets rapidly solidify to form a coating. This process, when carried out correctly,is called a cold process (relative to the substrate material b

216、eing coated) as thesubstrate temperature can be kept low during processing to avoid damage,Copyright BCC Research, Wellesley, MA USA, Web: 22AVM015EHighPerformance Ceramic Coatings: Markets and Technologiesmetallurgical changes and distortion to the substrate material. This process hasbeen used exte

217、nsively in the past, and is used today for machine element work andanticorrosion coatings. While metals and metallic alloys are the most commonlyused in the combustion wire thermal process, ceramics and cermets are also used inwire form to produce coatings.A system developed by St. Gobain/Norton (th

218、e Rokide process) uses fused ceramicmaterial in rod form, which is introduced through a 5,000 F flame. A highpressure air stream blows the atomized molten particles onto the substrate atspeeds up to 550 ft./sec. The sequential melting and projection of the ceramicmaterial is not concurrent, as it is

219、 in powderfeed spray methods. The largerparticles produced by the rod process have higher thermal mass, which producesfully molten particles at the substrate. This results in a coating with high particletoparticle cohesive bonding. Bonding to the substrate and particletoparticlebonding are key eleme

220、nts in producing highquality, highperformance ceramiccoatings.The process requires a low capital investment, is simple to operate, the wire form ischeaper than powder, deposit efficiency is very high, and the process is best suitedto particular cases, such as molybdenum coatings, for wear resistance

221、. Otheradvantages include portability, built in reheating facility (unlike arc spraying), andit is possible to use the system in areas without electricity.Features and BenefitsExcellent economyVersatile and reliableEasy to operateCoats large structures with minimal equipmentHigh production spray rat

222、esProcess can be automatedReliabilityDisadvantages of the process are its limitation to spraying materials supplied inwire or rod form, and it is not capable of providing the low oxide, highdensity andhighstrength coatings of plasma and HVOF.Typical ApplicationsAtmospheric and high temperature corro

223、sion controlRebuild and salvage operationsCopyright BCC Research, Wellesley, MA USA, Web: 23AVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesCOMBUSTION POWDER THERMAL SPRAY PROCESSPowder combustion thermal spray has been serving industries for decades witheconomical, reliable surface

224、s. Relatively low initial investment cost makes this anideal process for entrylevel thermal spray coating.This method is also known as powder flame spraying and a low velocity oxygen fuel(LVOF) process. It is basically the spraying of molten material onto a surface toprovide a coating.In this system

225、 powdered ceramics are fed into a flame at 500 F. Compressed airblows the heated particles onto the substrate. The ceramic material in powder formis partly melted in the flame (oxyacetylene or hydrogen are most common) to form afine spray. When the spray contacts the prepared surface of a substrate

226、material,the fine molten droplets rapidly solidify to form a coating. This process carried outcorrectly is called a cold process (relative to the substrate material being coated),as the substrate temperature can be kept low during processing to avoid damage,metallurgical changes and distortion to th

227、e substrate material.The main advantage of this process over the similar combustion wire spray processis that a much wider range of materials can be easily processed into powder formgiving a larger choice of coatings. Because powdered ceramic material remains incontact with the heat source for a ver

228、y short time, all the ceramic particles do notbecome completely molten. This results in a lowerperformance coating. Theprocess is only limited by materials with higher melting temperatures than theflame can provide, or if the material decomposes on heating. Table 7 lists materialsused in the powder

229、flame process.TABLE 7CERAMIC MATERIALS USED IN THE POWDER FLAME PROCESSMaterialWC/NiCrBSiAl2O3MgO/ZrO2 (magnesium zirconate)Zirconia/aluminaApplicationHigh wear resistanceElectrical and wear resistanceThermal barrier, erosion resistance, molten metalsThermal barrier, abrasion resistanceSource: BCC R

230、esearchCopyright BCC Research, Wellesley, MA USA, Web: 24AVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesFeatures and BenefitsGood economy with long consumable lifeVersatile and reliableEasy to operateRelatively low operational noiseLarge choice of coating materialsHigh production s

231、pray ratesProcess can be automatedPortabilityTypical ApplicationsRebuild and salvage operationsAbrasion resistanceSliding wear resistanceImpact resistanceResistance to chemical attackAtmospheric and high temperature corrosion controlELECTRIC ARC WIRE THERMAL SPRAY PROCESSElectric arc wire thermal sp

232、ray process is simple, fast and economical. Thesimplicity of this process, which uses electricity and compressed air, and the speedat which it applies coatings without fuel gas are the hallmarks of electric wire arcspraying.In the arc spray process, a pair of electrically conductive wires is melted

233、with anelectric arc. The molten material is atomized by compressed air and propelledtowards the substrate surface. The impacting molten particles on the substraterapidly solidify to form a coating. This process, similar to the combustion powderthermal spray process when carried out correctly, is cal

234、led a cold process (relativeto the substrate material being coated), as the substrate temperature can be keptlow during processing to avoid damage, metallurgical changes and distortion to thesubstrate material. Arc spray coatings are normally denser and stronger than theirequivalent combustion spray

235、 coatings. Low running costs, high spray rates andefficiency make it a good tool for spraying large areas and high production rates.Features and BenefitsMinimal facilities requiredCopyright BCC Research, Wellesley, MA USA, Web: 25AVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesMany

236、substrate materials can be coatedNo combustible gas supply is requiredAutomatic wire loadingVersatile and reliableEasy to operateLarge structures can be coatedExcellent coating bond strength and densityHigh production spray ratesProduces easily machinable coatingsProcess can be automatedPortabilityD

237、isadvantages of the process are that only electrically conductive wires can besprayed, and if substrate preheating is required, a separate heating source isneeded.Typical ApplicationsAtmospheric and heat corrosion controlRebuild and salvage operationsBond coatsElectrically conductive and solderable

238、coatingsAntiskid and traction coatingsPLASMA THERMAL SPRAY PROCESSPlasma is an electrically conductive gas containing charged particles. Plasma iscreated by passing a gas, usually argon, nitrogen, or a mixture of gases, through anelectric arc. When atoms of a gas are excited to high energy levels, t

239、he atoms losehold of some of their electrons and become ionized to produce a plasma containingelectrically charged particlesions and electrons. The plasma generated forspraying usually incorporates one of, or a mixture of: argon, helium, nitrogen andhydrogen.Plasma flames for thermal spraying can pr

240、oduce temperatures ranging from 7,000K to 20,000 K. These are far above the melting temperature (and vaportemperature) of any known material. The extreme temperature of the plasma is notthe only reason for its effective heating properties. If, for example, helium gas wereheated to around 13,000 K wi

241、thout forming a plasma it would have insufficientenergy for normal plasma spraying. Nitrogen on the other hand heated to 10,000 Kgoes through dissociation and ionization to form a plasma that is an effectiveheating media for thermal spraying. It is able to supply about six times moreCopyright BCC Re

242、search, Wellesley, MA USA, Web: 26AVM015EHighPerformance Ceramic Coatings: Markets and Technologiesenergy than helium at 13,000 K. The plasma is able to supply large amounts ofenergy due to the changes associated with dissociating molecular gases to atomicgases and the ionization that occurs with li

243、ttle change in temperature.Nitrogen and hydrogen are diatomic gases (two atoms to every molecule). Theseplasmas have higher energy contents for a given temperature than the atomic gasesof argon and helium because of the energy associated with dissociation of molecules.Argon and helium are monatomic

244、gases (the atoms do not combine to formmolecules). These plasmas are relatively lower in energy content and higher intemperature than plasmas from diatomic gases.Nitrogen is a generalpurpose primary gas used alone or with a hydrogen secondarygas. Nitrogen also benefits from being the cheapest plasma

245、 gas and tends to beinert to most spray material except materials like titanium. Argon is probably themost favored primary plasma gas and is generally used with a secondary plasmagas (hydrogen, helium and nitrogen) to increase its energy. Argon is the easiest ofthese gases to form a plasma and tends

246、 to be less aggressive towards electrode andnozzle hardware. Most plasmas are started with pure argon, which is a noble gasand completely inert to all spray materials.Hydrogen is used mainly as a secondary gas. It dramatically affects heat transferproperties and acts as an antioxidant. Small amounts

247、 of hydrogen added to theother plasma gases dramatically alters plasma characteristics and energy levelsand is thus used as one control for setting plasma voltage and energy.Helium is used mainly with argon as a secondary gas. Helium, a noble gas, iscompletely inert to all spray materials and is use

248、d when hydrogen or nitrogensecondary gases have deleterious effects. Helium imparts good heat transferproperties and offers high sensitivity for control of plasma energy. It is commonlyused for highvelocity plasma spraying of highquality carbide coatings whereprocess conditions are critical.Plasma T

249、hermal Spray Process (Continued)The plasma spray process is basically the spraying of molten or heat softenedmaterial onto a surface to provide a coating. Material in the form of powder isinjected into a very hightemperature plasma flame, where it is rapidly heated andaccelerated to a high velocity.

250、 The hot material impacts on the substrate surfaceand rapidly cools to form a coating. Although the plasma in the gun can reachtemperatures up to 30,000 F, the application temperature seldom exceeds 200 F.This is also an example of a cold process.Figure 2 shows a schematic of the plasma spray coatin

251、g technique. The plasma gunis comprised of a copper anode and tungsten cathode, both of which are watercooled. Plasma gas (argon, nitrogen, hydrogen, helium) flows around the cathodeand through the anode, which is shaped as a constricting nozzle. The plasma isCopyright BCC Research, Wellesley, MA US

252、A, Web: 27AVM015EHighPerformance Ceramic Coatings: Markets and Technologiesinitiated by a highvoltage discharge, which causes localized ionization and aconductive path for a DC arc to form between cathode and anode. Resistanceheating from the arc causes the gas to reach extreme temperatures, then di

253、ssociateand ionize to form a plasma. The plasma exits the anode nozzle as a free or neutralplasma flame (plasma does not carry electric current), which is quite different to theplasma transferred arc coating process, where the arc extends to the surface to becoated. When the plasma is stabilized and

254、 ready for spraying, the electric arcextends down the nozzle instead of shorting out to the nearest edge of the anodenozzle. This stretching of the arc is caused by a thermal pinch effect. Cold gasaround the surface of the watercooled anode nozzle, since it is electricallynonconductive, constricts t

255、he plasma arc and raises its temperature and velocity.Powder is fed into the plasma flame, most commonly via an external powder portmounted near the anode nozzle exit. The powder is so rapidly heated andaccelerated that spray distances can be in the order of 25 mm to 150 mm.FIGURE 2PLASMA SPRAY COAT

256、ING TECHNIQUESource: Proceedings of the 7th National Thermal Spray Conference, ASM InternationalCopyright BCC Research, Wellesley, MA USA, Web: 28AVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesPlasma spray performs where other processes cannot, and is the best choice forapplication

257、s where a variety of coatings must be applied. It is a good choice forhighquality ceramic coatings, metals and cermets. Plasma spray produces highperformance coatings that deliver workhorse durability and reliability.The plasma spray process is most commonly used in normal atmospheric conditionsand

258、referred to as APS. Some plasma spraying is conducted in protectiveenvironments using vacuum chambers that are normally backfilled with aprotective gas at low pressure. This is referred to as VPS or LPPS. Unlikecombustion processes, the plasma spraying technique uses very highmelting pointmaterials

259、such as refractory metals like tungsten, and ceramics like zirconia.Plasmasprayed coatings are generally much denser, stronger and cleaner than theother thermal spray processes with the exception of HVOF and detonationprocesses. Plasmaspray coatings probably account for the widest range of thermalsp

260、ray coatings and applications, making this process the most versatile.This method generally produces wellbonded, highdensity ceramic coatings.However, because of the short time that powders are exposed to heat, there maysometimes be incomplete melting of ceramic materials. Table 7 lists representati

261、vepowder flamesprayed materials and applications.Plasmaspray techniques are well established as a way of depositing corrosion,wearresistant and thermal barrier coatings of ceramics onto a substrate. Theplasma spraying technique combines particle melting, quenching, and consolidationinto a singlestep

262、 process. Finely powdered metals, ceramics, cermets orrefractories are fed into the ionized plasma stream. The powder is melted andaccelerated toward the base material. The particles impinge on the surface andform a highly dense interlocking structure.Plasma Thermal Spray Process (Continued)Vacuum p

263、lasma spraying, which occurs in a vacuum chamber, has recently beenused to deposit SiC coatings on graphite, and mullite coatings on silicon nitride foroxidation resistance. Vacuum plasma spraying is used for oxygensensitivematerials (including biomaterials) and to obtain certain properties.Plasma t

264、ransferred arc surfacing is another variation of plasma spraying. It usestwo independently adjustable arcs produced by a separate DC power source with aconstant current. High power can be used to increase the deposition rate to morethan 10 kg/h, making the process more suitable for large components.

265、 The processcan be used for coating automotive valves and shipping diesel engines to improvewear and protect from corrosion.Underwater plasma spraying, commonly used in offshore and marine applications,has a shorter plasma flame due to the high viscosity of the water. This results in acontrolled hea

266、t input to the substrate material, preventing a heataffected zoneCopyright BCC Research, Wellesley, MA USA, Web: 29AVM015EHighPerformance Ceramic Coatings: Markets and Technologiesduring the coating process. Because water provides a high cooling rate of substrateand coating, the process is being inv

267、estigated for other materials. For instance, TiCcoatings with hardness as high as 2,000 HV to 2,200 HV and a deposition efficiencyranging from 0.5 to 0.6 have been made, as have zirconia coatings with porosityranging from 6% to 25% and having a fused top layer.Plasma coatings may be as thin as 0.001

268、 in. or as thick as 0.25 in. A coating of0.010 in. to 0.015 in. usually provides the required wear or corrosion resistance.Coating thickness is achieved by making multiple passes with the plasma spraygun. Plasma coatings can be used with almost any base material to achieve thedesired properties of m

269、ore costly material. Coating can also be used to rebuild wornmachinery at a fraction of the time and cost it would take to replace or repair.One of the major applications for plasmasprayed coatings is as a thermal barriercoating, otherwise known as a strainisolated ceramic coating. The primarycerami

270、c material used today for plasma flamesprayed thermal barrier coatings iszirconia. Zirconia (ZrO2) is used because of its relatively low thermal conductivity,its high melting temperature (3,900 F) and its good thermal shock resistance. Astabilized form of zirconia is used to prevent cracking of the

271、zirconia coating duringphase transformation. The major phase stabilizers used for zirconia are MgO, CaO,and Y2O3. Yttrium oxide (Y2O3) is the primary stabilizer used for zirconia in todaysapplications.The zirconia ceramic coating is applied by plasma flame spraying onto thesubstrate. In the plasmasp

272、raying technique, zirconia powder is heated to itsmelting point in a gas plasma. The coating is formed as the molten zirconiadroplets splatter on the cold substrate. As with other plasmaspray coatings, thesubstrate to be coated is grit blasted to roughen the surface followed by plasmaspraying with a

273、bout 0.003 in. of bond coat, which further enhances attachment ofthe ceramic. Grit blasting and bond coat applications are standard plasmaspraying techniques for enhancing coating attachment. A bond coat such as 0.003in. of NiCrAl powder provides a good substrate for zirconia attachment. Gritblastin

274、g and a thin bond coat are also useful before attaching the ceramic to aporous fiber metal strain isolator. The bond coat roughens the fiber surfaces forgood ceramic attachment and the ceramic penetrates into the fiber pore structure aswell.Features and BenefitsHigh degree of flexibilityVersatileLar

275、gest choice of coating materialsHigh production spray ratesCopyright BCC Research, Wellesley, MA USA, Web: 30AVM015EHighPerformance Ceramic Coatings: Markets and TechnologiesProcess can be highly automatedAdvantages of plasmasprayed coatings over other coating processes are:High particle velocities

276、result in higher strength coupled with highercoating density.The heat source is more efficient, because plasma, due to dissociation andionization processes, is at a very highenergy state. For this reason, highenergy is supplied to the powder particles accompanied by a minimumtemperature drop in the

277、surrounding gas stream, thus providing efficientparticle heating.The heating source is inert, minimizing oxidation.High plasmatemperature permits the spraying of materials with highmelting points.Among the disadvantages of plasmasprayed coatings are:Consistency and compositional uniformity of a coat

278、ing over a large area,at times, can vary.Spraying tends to produce porous coatings, especially when used at highvelocities due to gas entrapment.Reactive materials cannot be sprayed in open air; however, lowpressureplasma spraying (LPSS) can be used in these cases.The deposits contain oxidation prod

279、ucts, together with some porosity dueto incomplete melting, wetting, and/or fusing of deposited particles.The process is relatively expensive and complex.Typical ApplicationsRebuild and salvage operationsAbrasion or erosion resistanceSliding wear resistanceResistance to fretting, galling or adhesive wearResistance to cavitation effectsImpact resistanceResistance to chemical attackCopyright BCC Research, Wellesley, MA USA, Web: Fulltext of this report , contact with: QQ 147800822or Email to : 报告全文、价格请联系QQ：147800822Email：