The global market for thermal barrier coatings (TBCs) totaled $834.9 million in 2016 and should total nearly $1.1 billion in 2021 at a five-year compound annual growth rate (CAGR) of 5.6%, through 2021.
Report Scope:
The scope of this report is comprehensive, covering the present status of and future prospects for thermal barrier coating technologies. The scope of the report includes thermal barrier coating technologies applied to gas turbines for aircraft, gas turbines for power generation and industrial gas turbines and diesel engines for marine and other application.
The report identifies and evaluates thermal barrier coating technology markets with keen potential for growth. The study also provides extensive quantification of the many important facets of market developments for advanced thermal barrier coating technologies development.
In addition to thermal barrier coating technologies, it also covers the many issues concerning the merits and future prospects of the thermal barrier coating technologies business, including corporate strategies, information technologies and the means for providing these highly advanced products and service offerings. It also covers in detail the economic and technological issues regarded by many as critical to the industry’s current state of change.
The report provides a review of the thermal barrier coating technologies industry and its structure, and the OEMs, MROs, manufacturers of PMA equipment and surface technology expert coaters involved in providing these coatings. The competitive position of the main players in the TBC market is well protected due to license restrictions by OEMs (e.g., GE Aviation, Pratt & Whitney, Rolls-Royce, Safran) for sharing TBC solutions for hot section gas turbine for aircraft, particularly the high-pressure blades and vanes.
Manufacturers of PMA parts have received approval through aircraft regulating agencies such as the Federal Aviation Administration (FAA), European Aviation Safety Agency (EASA) and National Aero and Defense Contractors Accreditation Program (Nadcap). This has narrowed down the competition in TBC related solutions applied to gas turbines used in aircraft. On the other hand, gas turbines used in the power generation industry and other industrial stationary applications have a large number of approved MROs globally to repair and recoat the thermal barrier coatings on the hot section of gas turbines that undergo high-pressure blade/vane repair. These MROs follow approved quality certification procedures of OEMs (e.g., GE, Siemens, Rolls-Royce) for the bond coat and top coat.
The forecast tables represent the estimated value of the thermal barrier coating technologies added to the components of gas turbines and diesel engines as manufactured by the OEMs, MROs, PMA parts companies and coaters. In this report, the term revenue is equivalent to, and is used interchangeably with purchases, demand and sales. All growth rates mentioned in the tables and text are based on compound annual growth rates (CAGRs) from 2016 through 2021. Because current 2016 dollar measures are used, these growth rates thus reflect the growth in volume or real growth, including the effects of price changes and changes in product/service mix.
Report Includes:
- An overview of the global markets for thermal barrier coatings (TBC)
- Analyses of global market trends, with data from 2015 and 2016, and projections of compound annual growth rates (CAGRs) through 2021
- Provide a detailed and comprehensive multi-client study of the market for thermal barrier coating technologies
- Extensive quantification of the important facets of market developments in the industry
- Discussion of the merits and future prospects of the thermal barrier coating technologies business
- Overview of international U.S. patents pertaining to TBC technology
- Profiles of major manufacturers and suppliers related to TBC
REASONS FOR DOING THE STUDY
Maximizing business opportunities in the thermal barrier coating technologies arena is a challenging task. Significant changes are taking place within this industry, which in
the past, has been dominated by a few multinational OEM (original equipment manufacturers), MRO (maintenance repair and overhaul) and PMA (Parts Manufacturer
Approval) equipment providers and surface technology expert coating companies with a “niche” technology to address the hot section of aircraft, power generation gas
turbines and marine diesel engines. Many external forces, including new developments in gas turbine technology, new thermal barrier solutions and new coating architectures, have driven the shift in the industry trend that is taking place.
SCOPE OF THE REPORT
The scope of this report is comprehensive, covering the present status of and future prospects for thermal barrier coating technologies. The scope of the report includes
thermal barrier coating technologies applied to gas turbines for aircraft, gas turbines for power generation and industrial gas turbines and diesel engines for marine and
other application.
The report identifies and evaluates thermal barrier coating technology markets with keen potential for growth. The study also provides extensive quantification of the many important facets of market developments for advanced thermal barrier coating technologies development.
In addition to thermal barrier coating technologies, it also covers the many issues concerning the merits and future prospects of the thermal barrier coating technologies
business, including corporate strategies, information technologies and the means for providing these highly advanced products and service offerings. It also covers in detail
the economic and technological issues regarded by many as critical to the industry’s current state of change.
The report provides a review of the thermal barrier coating technologies industry and its structure, and the OEMs, MROs, manufacturers of PMA equipment and surface
technology expert coaters involved in providing these coatings. The competitive position of the main players in the TBC market is well protected due to license restrictions by OEMs (e.g., GE Aviation, Pratt & Whitney, Rolls-Royce, Safran) for sharing TBC solutions for hot section gas turbine for aircraft, particularly the high-pressure blades and vanes.
Manufacturers of PMA parts have received approval through aircraft regulating agencies such as the Federal Aviation Administration (FAA), European Aviation Safety
Agency (EASA) and National Aero and Defense Contractors Accreditation Program (Nadcap). This has narrowed down the competition in TBC related solutions applied to
gas turbines used in aircraft. On the other hand, gas turbines used in the power generation industry and other industrial stationary applications have a large number of
approved MROs globally to repair and recoat the thermal barrier coatings on the hot section of gas turbines that undergo high-pressure blade/vane repair. These MROs
follow approved quality certification procedures of OEMs (e.g., GE, Siemens, Rolls-Royce) for the bond coat and top coat.
The forecast tables represent the estimated value of the thermal barrier coating technologies added to the components of gas turbines and diesel engines as
manufactured by the OEMs, MROs, PMA parts companies and coaters. In this report, the term revenue is equivalent to, and is used interchangeably with purchases,
demand and sales. All growth rates mentioned in the tables and text are based on compound annual growth rates (CAGRs) from 2016 through 2021. Because current
2016 dollar measures are used, these growth rates thus reflect the growth in volume or real growth, including the effects of price changes and changes in product/service mix.
Table of Contents
Chapter 1 INTRODUCTION
STUDY GOAL AND OBJECTIVES
REASONS FOR DOING THE STUDY
INTENDED AUDIENCE
SCOPE OF THE REPORT
METHODOLOGY
INFORMATION SOURCES
ANALYST'S CREDENTIALS
RELATED BCC RESEARCH REPORTS
BCC RESEARCH WEBSITE
DISCLAIMER
Chapter 2 EXECUTIVE SUMMARY
Chapter 3 OVERVIEW
COMPETITIVE LANDSCAPE AND KEY VENDORS
COMPETITIVE LANDSCAPE AND KEY VENDORS
AIRCRAFT INDUSTRY
OEMs
MROs
PMA Parts Providers
POWER GENERATION INDUSTRY AND INDUSTRY USE OF GAS TURBINES
OEMs
MROs
PMA Parts Providers
MARINE DIESEL ENGINES
Chapter 4 MARKET SEGMENTATION
THERMAL BARRIER COATING MARKET BY ARCHITECTURE
THERMAL BARRIER COATING MARKET BY APPLICATION INDUSTRY
BASIS OF THE CALCULATION OF THE MARKET SIZES OF INDUSTRY APPLICATIONS OF TBC IN 2016
Aircraft Industry
Power Generation Industry and Industrial Gas Turbines
Marine Diesel Engine Industry
THERMAL BARRIER COATING MARKET BY DEPOSITION PROCESS
THERMAL BARRIER COATING MARKET BY DEPOSITION PROCESS
EB-PVD Thermal Barrier Coatings
LPPS Thermal Barrier Coatings
APS Thermal Barrier Coatings
HVOF Thermal Barrier Coatings
THERMAL BARRIER COATING MARKET BY TYPE OF PROVIDER
AIRCRAFT APPLICATIONS BY TYPE OF PROVIDER
Global Market
Regional Markets
POWER GENERATION APPLICATIONS BY TYPE OF PROVIDER
Global Market
Regional Markets
THERMAL BARRIER COATINGS IN MARINE DIESEL ENGINE APPLICATIONS BY TYPE OF PROVIDER
Global Market
Regional Markets
TBC APPLICATIONS IN THE HOT SECTION COMPONENTS OF AIRCRAFT GAS TURBINES BY FIRING TEMPERATURE
GLOBAL MARKET
APPLICATION SEGMENTS BY REGION
Aircraft Turbine Engines with a Firing Temperature of 1,400?C
Aircraft Engines with a Firing Temperature of 1,350?C
Aircraft Engines with a Firing Temperature of 1,300?C
Aircraft Engines with a Firing Temperature of 1,250?C
Aircraft Engines with a Firing Temperature of 1,200?C
Aircraft Engines with a Firing Temperature below 1,200?C
TBC APPLICATIONS IN THE HOT SECTION OF POWER GENERATION GAS TURBINES AND INDUSTRIAL GAS TURBINES BY FIRING TEMPERATURE
GLOBAL MARKET
APPLICATION SEGMENTS BY REGION
Power Generation Gas Turbine Engines with a Firing Temperature of 1,800?C
Power Generation Gas Turbine Engines with a Firing Temperature of 1,750?C
Power Generation Gas Turbine Engines with a Firing Temperature of 1,700?C
Power Generation Gas Turbine Engines with a Firing Temperature of 1,650?C
Power Generation Gas Turbine Engines with a Firing Temperature of 1,600?C
Power Generation Gas Turbine Engines with a Firing Temperature of 1,550?C
Power Generation Gas Turbine Engines with a Firing Temperature of 1,500?C
Power Generation Gas Turbine Engines with a Firing Temperature of 1,450?C
Power Generation Gas Turbine Engines with a Firing Temperature of 1,400?C
Power Generation Turbine Engines with a Firing Temperature below 1,400?C
TBC APPLICATIONS IN MARINE DIESEL ENGINES BY FIRING TEMPERATURE
APPLICATION SEGMENTS BY REGION
Marine Diesel Engines with a Firing Temperature of 650?C
Marine Diesel Engines with a Firing Temperature of 600?C
Marine Diesel Engines with a Firing Temperature of 550?C
Marine Diesel Engines with a Firing Temperature of 500?C
Marine Diesel Engines with a Firing Temperature below 500?C
Chapter 5 TECHNOLOGY OVERVIEW
ROLE OF HIGH INTAKE GAS TEMPERATURE TO OBTAIN HIGHER GAS TURBINE EFFICIENCY
GAS TURBINE ENGINES CONCEPT AND CONSTRUCTION HOT SECTION COMPONENTS
STAGES
COMBUSTION HARDWARE
Nozzles and Vanes
Stage 1 Vanes
Stage 2 Vanes
Stage 3 Vanes
Stage 4 Vanes
GE Gas Turbine
BLADES AND BUCKETS
Stage 1 Blades
Stage 2 Blades
Stage 3 Blades
Stage 4 Blades
GE Gas Turbine
OPERATING MECHANISM OF OXIDATION AND CORROSION AND ROLE OF TBC IN THE HOT SECTION COMPONENTS OF GAS TURBINES
DIFFUSION COATING VERSUS OVERLAY COATINGS
ROLE OF EACH ELEMENT OF HIGH TEMPERATURE OXIDATION AND CORROSION RESISTANT COATINGS
TYPES AND STRUCTURES OF TBC IN AEROSPACE GAS TURBINE ENGINES
BOND COAT MATERIAL OPTIONS AND PROPERTIES
Major Types of Bond Coats
Aluminide Bond Coat
MCrAlY Bond Coat
Cobalt-Cermet-Based Coatings
Nickel-Chromium Bond Coat
TOP COAT MATERIAL OPTIONS AND PROPERTIES
Yttria-Stabilized Zirconia
Mullite
Alumina
CeO2 + YSZ
Rare-Earth Zirconates
Rare-Earth Oxides
Metal-Glass Composites
ROLE OF THERMALLY GROWN OXIDES
PROCESS OPTIONS FOR BOND COAT AND TOP COAT
Air Plasma Spraying
High-Velocity Oxygen Fuel
Low Pressure Plasma Spray
Electron Beam-Physical Vapor Deposition
Process Description
Advantages and Disadvantages of EB-PVD
Description of EB-PVD Production Systems Coating Machines
Process Control
FUTURE ADVANCES
COMPARATIVE ANALYSIS OF BOND COAT PROCESSES
COMPARATIVE ANALYSIS OF TOP COAT PROCESSES
DEGRADATION OF HOT SECTION COMPONENTS
Creep
Thermal Mechanical Fatigue
Metallurgical Embrittlement
Environmental Attack and Coating Degradation
Oxidation
Hot Corrosion
Coating Degradation
REPAIR OF HOT SECTION COMPONENTS
RECOATING
Chapter 6 THERMAL BARRIER COATING APPLICATIONS
THERMAL BARRIER COATINGS IN AIRCRAFT GAS TURBINE ENGINE APPLICATIONS
CASE STUDY-PRATT & WHITNEY
ROLE OF THICKNESS OF THERMAL BARRIER COATING
CASE STUDY-ROLLS-ROYCE
CASE STUDY-MTU AERO ENGINES-CERAMIC COATING CENTER, FRANCE
CASE STUDY-ELECTRIC WELDING INSTITUTE OF THE NATIONAL ACADEMY OF SCIENCE OF UKRAINE
THERMAL BARRIER COATINGS USED IN POWER GENERATION GAS AND INDUSTRIAL GAS TURBINE (IGT) ENGINES
CRITERION FOR CHOOSING THE TBC ARCHITECTURE FOR POWER GENERATION GAS TURBINES
Quality of Fuels
Oxide Scale
Coating Life
TBC APPLICATIONS IN POWER GENERATION GAS TURBINE ENGINES
Combustor of Gas Turbine for Power Generation
Vane Airfoils
Vane Platforms
BLADE AIRFOILS AND PLATFORMS
MULTILAYERED CERAMIC TBC
LANTHANUM ZIRCONATE
GADOLINIUM ZIRCONATE
CASE STUDIES
Cooling Technology for Hot Section of Gas Turbine Adopted for Power Generation by Mitsubishi Hitachi Power Systems
GTCC Power Generation
Cooling Technology of Hot Section of GTCC Gas Turbine
SIEMENS INDUSTRIAL TURBOMACHINERY AB
Coating Solutions at Sulzer Turbo Services Venlo BV, Netherland
Combined Role of TBC and Cooling Technologies in HP Blades of Gas Turbines Used in IGCC at MHI
GTCC-Related Turbine Features
Gas Turbine with a Firing Temperature of 1,600°C-Forschungszentrum Jülich GmbH Germany
THERMAL BARRIER COATINGS IN DIESEL ENGINES
MARINE APPLICATIONS
OEM APPLICATIONS
HOW EMISSION REDUCTIONS ARE ACHIEVED WITH TBC?
ADVANTAGES OF TBC IN DIESEL ENGINES
Chapter 7 PATENTS
OVERVIEW
U.S. PATENT ACTIVITY IN TBC TECHNOLOGY BY ASSIGNEE COUNTRY
U.S. PATENTS ON THERMAL BARRIER COATING TECHNOLOGY
Patent Title: Combustor resonator section with an internal thermal barrier coating and method of fabricating the same
PATENT TITLE: PROCESS OF FABRICATING THERMAL BARRIER COATINGS
PATENT TITLE: METHOD OF FABRICATING A THERMAL BARRIER
PATENT TITLE: GERMANATE-CONTAINING THERMAL BARRIER COATING
PATENT TITLE: THERMAL BARRIER COATINGS INCLUDING CMAS-RESISTANT THERMAL BARRIER COATING LAYERS
PATENT TITLE: THERMAL BARRIER COATINGS AND METHODS OF APPLICATION
PATENT TITLE: THERMAL BARRIER COATING SYSTEM, COMPONENTS COATED THEREWITH AND METHOD FOR APPLYING A THERMAL BARRIER COATING SYSTEM TO COMPONENTS
PATENT TITLE: METHOD FOR MANUFACTURING A THERMAL-BARRIER PROTECTION AND MULTILAYER COATING SUITABLE FOR FORMING A THERMAL BARRIER
PATENT TITLE: TECHNIQUES FOR REMOVING A CONTAMINANT LAYER FROM A THERMAL BARRIER COATING AND ESTIMATING REMAINING LIFE OF THE COATING
PATENT TITLE: METHOD FOR COATING A BLADE AND BLADE OF A GAS TURBINE
PATENT TITLE: METHOD AND APPARATUS FOR FABRICATION AND REPAIR OF THERMAL BARRIERS
PATENT TITLE: HIGH PURITY ZIRCONIA-BASED THERMALLY SPRAYED COATINGS AND PROCESSES FOR THE PREPARATION THEREOF
PATENT TITLE: THERMAL BARRIER COATING METHOD, MASKING PIN AND COMBUSTOR TRANSITION PIECE
PATENT TITLE: ARTICLE HAVING THERMAL BARRIER COATING
PATENT TITLE: THERMAL BARRIER COATING SYSTEMS AND PROCESSES THEREFOR
PATENT TITLE: TRI-BARRIER CERAMIC COATING
PATENT TITLE: PLASMA-SPRAY POWDER MANUFACTURE TECHNIQUE
PATENT TITLE: METHODS AND SYSTEMS FOR CONTROLLING THERMAL DIFFERENTIAL IN TURBINE SYSTEMS
PATENT TITLE: THERMAL BARRIER COATING METHOD, MASKING PIN AND COMBUSTOR TRANSITION PIECE
PATENT TITLE: METHOD FOR REFURBISHING PTAL COATING TO TURBINE HARDWARE REMOVED FROM SERVICE
PATENT TITLE: LASER DRILLING METHODS OF SHALLOW-ANGLED HOLES
PATENT TITLE: DAMAGE RESISTANT THERMAL BARRIER COATING AND METHOD
PATENT TITLE: METHODS AND SYSTEMS TO THERMALLY PROTECT FUEL NOZZLES IN COMBUSTION SYSTEMS
PATENT TITLE: HIGH-PURITY FUSED AND CRUSHED ZIRCONIA ALLOY POWDER AND METHOD OF PRODUCING SAME
PATENT TITLE: THERMAL BARRIER COATING MEMBER, METHOD FOR PRODUCING THE SAME, THERMAL BARRIER COATING MATERIAL, GAS TURBINE, AND SINTERED BODY
PATENT TITLE: LAYERED THERMAL BARRIER COATING WITH BLENDED TRANSITION AND METHOD OF APPLICATION
PATENT TITLE: OXIDE COATING FOUNDATION FOR PROMOTING TBC ADHERENCE
PATENT TITLE: THERMAL BARRIER COATING APPLICATION PROCESSES
PATENT TITLE: EROSION BARRIER FOR THERMAL BARRIER COATINGS
PATENT TITLE: APPLICATION OF DENSE VERTICALLY CRACKED AND POROUS THERMAL BARRIER COATING TO A GAS TURBINE COMPONENT
PATENT TITLE: LIFE MANAGEMENT SYSTEM AND METHOD FOR GAS TURBINE THERMAL BARRIER COATINGS
PATENT TITLE: METHOD FOR APPLYING A THERMAL BARRIER COATING
PATENT TITLE: MULTILAYER THERMAL BARRIER COATINGS
PATENT TITLE: HIGH-TEMPERATURE RESISTANT COMPONENT AND GAS TURBINE HOT PART
PATENT TITLE: METHOD FOR FORMING THERMAL BARRIER COATING ON HOT GAS-PATH COMPONENTS OF GAS TURBINE DURING OPERATION
PATENT TITLE: HIGH PURITY ZIRCONIA-BASED THERMALLY SPRAYED COATINGS
PATENT TITLE: METHODS AND APPARATUS FOR THERMAL BARRIER COATINGS WITH IMPROVED OVERALL THERMAL INSULATION CHARACTERISTICS
PATENT TITLE: SEGMENTED THERMAL BARRIER COATING
PATENT TITLE: METHODS FOR THE PROTECTION OF A THERMAL BARRIER COATING SYSTEM AND METHODS FOR THE RENEWAL OF SUCH A PROTECTION
PATENT TITLE: THERMAL BARRIER COATINGS AND ARTICLES MADE THEREFROM
PATENT TITLE: PROCESS FOR EXTENDING THE CYCLIC SERVICE LIFE OF THERMAL BARRIER COATINGS, IN PARTICULAR ON GAS TURBINE COMPONENTS
PATENT TITLE: PYROCHLORE MATERIALS AND A THERMAL BARRIER COATING WITH THESE PYROCHLORE MATERIALS
Chapter 8 INDUSTRY STRUCTURE
COMPETITIVE LANDSCAPE AND KEY VENDORS
AIRCRAFT INDUSTRY
OEMs
Ceramic Coating Center SAS
MROs
Pratt & Whitney Global Material Solutions
Chromalloy
CTS Engines
MTU Repair Services
Lufthansa Technik AG
Manufacturers of PMA Parts for Aircraft Gas Turbines
POWER GENERATION INDUSTRY
OEMs
MROs
PW Power Systems Inc.
Mitsubishi Hitachi Power Systems
PMA Parts
Sulzer
MARINE DIESEL ENGINES
INDUSTRY DEVELOPMENTS
JOINT VENTURES
MERGERS AND ACQUISITIONS
RECENT TBC COMPANY EXPANSIONS
Chapter 9 COMPANY PROFILES
OEM SUPPLIERS OF AIRCRAFT GAS TURBINES
OEM SUPPLIERS OF POWER GENERATION GAS TURBINES
MRO SERVICE PROVIDERS FOR AIRCRAFT GAS TURBINES
MRO PROVIDERS FOR POWER GENERATION GAS TURBINES
MRO PROVIDERS FOR BOTH AIRCRAFT AND POWER GENERATION GAS TURBINES
PMA PROVIDERS OF AIRCRAFT PARTS
PMA PROVIDERS OF PARTS FOR POWER GENERATION GAS TURBINES
INDEPENDENT TBC COATERS OF BOTH AIRCRAFT AND POWER GENERATION GAS TURBINES
MANUFACTURERS/SUPPLIERS OF TBC MATERIALS AND COATING EQUIPMENT
CERAMIC COATING CENTER SAS
GE AVIATION
MTU AERO ENGINES AG
PRATT & WHITNEY
ROLLS-ROYCE CORP.
TURBOCOATING S.P.A.
ANSALDO ENERGIA
GENERAL ELECTRIC (SWITZERLAND) GMBH
MITSUBISHI HITACHI POWER SYSTEMS LTD. (MHPS)
SIEMENS INDUSTRIAL TURBOMACHINERY AB
SOLAR TURBINES INC.
TURBINE AIRFOIL COATING AND REPAIR GMBH (TACR GMBH)
TOSHIBA CORP.
CTS ENGINES
LUFTHANSA TECHNIK AG
MTU MAINTENANCE HANNOVER GMBH
PRATT & WHITNEY GLOBAL SERVICE PARTNERS (GSP)
SNECMA AMERICA ENGINE SERVICES (SAMES)
SIA ENGINEERING CO. LTD. (SIAEC)
ALLIED POWER GROUP LLC
ETHOSENERGY
LIBURDI ENGINEERING
OERLIKON METCO AG
PW POWER SYSTEMS INC.
SULZER TURBO SERVICES HOUSTON INC.
SULZER TURBO SERVICES VENLO BV
MTU AEROENGINES AG
BELAC LLC
CHROMALLOY
MAPNA TURBINE BLADE ENG. & MFG.-PARTO
PT. SULZER INDONESIA
BODYCOTE
CHROMALLOY
ELLISON SURFACE TECHNOLOGIES
FLAME SPRAY TECHNOLOGIES B.V.
JARVIS AIRFOIL INC.
PRAXAIR SURFACE TECHNOLOGIES GMBH
SWAIN TECH COATINGS INC.
ALD VACUUM TECHNOLOGIES GMBH
BASF CATALYSTS LLC
ETS POWER GROUP INC.
H.C. STARCK GMBH
PROGRESSIVE SURFACE
RGE (RAJPUROHIT GROUP OF ENTERPRISES)
SAINT-GOBAIN CERAMIC MATERIALS GMBH
SANDVIK OSPREY LTD.
ZIRCOTEC LTD.
GE Aviation Plant 2
U.S. Facility
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