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Mullite Coatings Market Overview
Mullite Coatings market size is forecasted to grow at a CAGR of 4.5% during 2022-2027. Mullite is a compound of silica and alumina with low density, high-temperature stability, favorable strength, and creep behavior. Mullite with the formula 3Al2O3·SiO2 is the only stable crystallized silica-alumina compound. It is also known as porcelanite. Mullite coatings are used as protective coatings, architectural coatings, and thermal insulation coatings. Due to its properties such as good mechanical strength, high thermal stability, low thermal conductivity, and corrosion and oxidation resistance, mullite is suitable as a zirconia alternative for applications such as diesel engines, where surface temperatures are low and temperature variations across the coating could be large. One of the prominent trends the market is witnessing is the implementation of regulations with regard to automotive parts and the rapid pace of industrialization in Asia. Hence, the demand for mullite coatings is expected to rise during the forecast period.
COVID-19 Impact
COVID-19 has affected every industry. The construction industry was also not spared. The construction industry has seen many ups and downs throughout the pandemic. Construction came to a complete standstill due to lockdown measures and stay-at-home mandates. On the other hand, as the number of cases was rising, hospitals were full and countries resorted to the construction of new hospitals, some were even constructed in a record few weeks. After the initial lockdown when economic activities were allowed, the construction industry still faced challenges in the form of supply chain disruptions and operational constraints. Some building-materials supply chains have also been interrupted, suspending production and distribution. This in turn has also affected the mullite coatings market.
Report Coverage
The report: “Mullite Coatings Market – Forecast (2022-2027)”, by IndustryARC, covers an in-depth analysis of the following segments of the Mullite Coatings Market.
Key Takeaways
- Asia-Pacific dominates the mullite coatings market, owing to the increasing construction activity in the region. According to Invest India, the construction industry is expected to reach $1.4 trillion by 2025.
- Mullite coatings are suitable for applications requiring good dielectric strength, thermal insulation, and aluminum metal contact.
- Mullite’s main use is as a thermal barrier coating in diesel engine parts.
- The major opportunity for this market is high research spending and lowering the cost as mullite coatings are non-toxic and therefore might be able to replace some of the traditional protective coatings.
Figure: Asia-Pacific Mullite Coatings Market Revenue, 2021-2027 (US$ Billion)
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Mullite Coatings Market Segment Analysis – By Purity
The 99.95% segment held a significant share in the mullite coatings market in 2021. Mullite or Porcelanite is a rare silicate mineral. It has two stoichiometric forms 3Al2O3.2SiO2 or 2Al2O3.SiO2. The most commonly used form is 3Al2O3.2SiO in purity ranging from 98.0% to 99.95%. The properties of mullite such as low thermal conductivity and expansion coefficient and high phase stability make it ideal for environmental barrier coatings topcoats to protect ceramic matrix composites. 99.95% pure mullite powder is utilized for mainly aerospace and automotive coatings. Therefore, the 99.95% purity segment is expected to hold a significant share during the forecast period.
Mullite Coatings Market Segment Analysis – By Product Type
The ceramics segment held the largest share more than 70% share in the mullite coatings market in 2021. As mullite has the following properties as high creep resistance, low thermal expansion coefficient, and thermal conductivity, excellent corrosion resistance, and thermal shock resistance, it plays an important role in the coating of traditional ceramics and advanced ceramic materials. Mullite coating ceramics also have good electrochemical and optical properties. Monolithic mullite coated ceramics are a good high-temperature structural material, therefore they are widely employed in the aerospace industry. Many metals and ceramics get degraded under high-temperature environments. Surface coating technology is used to protect these materials at high temperatures, also known as environmental barrier coatings (EBCs). Mullite EBCs have been used for high temperature oxidation protection of oxide or non-oxide-based ceramics. Hence, the high demand from the ceramics segment is expected to drive the mullite coatings market.
Mullite Coatings Market Segment Analysis – By Application
The insulation coating segment held the largest share of more than 55% in the mullite coatings market in 2021. Insulation coatings act as a protective barrier against heat. Thermal insulation is done in various applications to be able to withstand the variation in the temperatures. Insulation coatings maintain energy consumption and increase efficiency. Mullite is one of the commonly used insulating coatings. These are applied to surfaces exposed to temperature changes and can resist thermal and shock absorptions. They provide longer shelf life to the substrates. Protection of equipment and components from external environments to make them energy efficient is the reason behind the rise of insulation coatings. Hence, the insulation coatings segment is expected to dominate the mullite coatings market during the forecast period.
Mullite Coatings Market Segment Analysis – By End-Use Industry
The automotive segment held the largest share up to 26% in the mullite coatings market in 2021. The need for improved fuel efficiency and reduced carbon emissions from diesel engines has always been a need for the automotive industry. Using plasma spray to apply a thermal insulation coating on parts of the combustion chamber of the engine is one way of achieving this. Technological advances made it possible now to find ceramic-coated components in modern engines and on high-performance components in race cars such as the cars used in Formula 1, NASCAR, World Rally, among others. Apart from providing thermal protection, mullite coatings are also used to prevent the degradation of the composite material due to friction. This is made possible as the ceramic material bonds with the composite, not just on the surface. This forms a tough coating that doesn't chip off like paint. Therefore, the demand from the automotive sector is projected to fuel the mullite coatings market.
Mullite Coatings Market Segment Analysis – By Geography
The Asia-Pacific region held the largest share in the mullite coatings market in 2021 up to 42%, owing to the growing automotive and aerospace industries in the region. The increasing working-class population are boosting the industrial growth in the region. According to the OECD Labour Force Statistics, the working-class population in China, India and Korea were 70.3%. 67.3% and 72.1% in 2020. This creates lucrative growth opportunities in the market. After the pandemic slump, as the vaccination pace is picking up the aerospace industry in Asia is beginning to revive. According to Boeing's 2020 Commercial Market Outlook (CMO), Southeast Asian passenger traffic will rise at a rate of 5.7% per year until 2039. Thus, with the flourishing aerospace industry, there will be an upsurge in the demand for aerospace components, which is anticipated to drive the mullite coatings market in the Asia-Pacific region.
Mullite Coatings Market Drivers
Implementation of Regulations are Driving the Consumption of Mullite Coatings
The high creep resistance, low thermal expansion coefficient and thermal conductivity, excellent corrosion resistance, and thermal shock resistance properties make mullite coatings ideal for diesel engine parts. Diesel engines are used in various types of vehicles as diesel is the most energy-efficient internal combustion engine. The legal requirements for diesel engines have been tightened several times. The US Environmental Protection Agency (EPA) formulates regulations that govern the efficiency of automotive vehicles. The improvement in performance required by newer vehicles has paved the way for the use of mullite coatings. Thus, increasing automation production will require more automotive components, which will act as a driver for the mullite coatings market during the forecast period.
Rapid Industrialization in Asian Countries
Demand for thermal insulation coatings is rising because of Asia’s growing manufacturing, construction, aerospace, transport, and automotive industries. According to the Singapore Economic Development Board (EDB), Singapore is one of Asia’s largest and most diverse concentrations of aerospace companies with over 130 aerospace players. Thereby, earning the title of aerospace city of the future. According to the Financial Times, Singapore outperformed every other city in getting investments and is an attractive location for innovation in the aerospace industry. Changi Airport in Singapore was voted the world's best airport for 8 years consecutively by Skytrax, a UK firm that ranks and reviews airports and airlines. China has resorted to fresh efforts in advancing the construction of new infrastructure projects in a bid to stimulate the economy after the pandemic slump and to boost industrial upgrading. China plans to issue about $529 billion of special local government bonds with priority for new infrastructure, urbanization, and major projects, according to a government work report. Hence, the rapid industrialization in Asian countries will act as a driver for the mullite coatings market.
Mullite Coatings Market Challenges
Availability of Raw Materials and Fluctuation in Prices
Mullite coatings are used as protective or insulation coatings against heat and they also help in energy savings. Factors responsible for fluctuation in raw material prices are the capital involved in synthesis and manufacturing. Mullite occurs naturally but is very rare. So, it is synthesized by various processes including the sol-gel method. The price of mullite ranges between $50-$150 per ton. Thermal insulation coating in the form of a thin film coating provides excellent insulation that reduces energy consumption for heating or cooling. The better formulation of such coatings to withstand any harsh conditions in order to protect the coated component from high temperature and corrosion tends to increase the demand of the market. But the technology used to coat such parts and components are expensive. These factors can prove to be a challenge for the mullite coatings market.
Mullite Coatings Market Landscape
Technology launches, acquisitions, and R&D activities are key strategies adopted by players in the Mullite Coatings market. Mullite Coatings market top companies include:
- Saint Gobain Coating Solutions
- Nippon Paint Company Ltd
- Axalta Coating System
- The Jotun Group
- PPG Industries
- Sherwin-Williams Company
- Kansai Paint
- Mascoat Insulation Coatings
- Sharp Shell Industries
- KCM Corporation
Acquisitions/Technology Launches
In September 2019, Nippon Paint Inc., a subsidiary of Nippon Paint Holdings Co., Ltd., invested around $60 million to set up a factory to manufacture automotive coatings in Chattanooga, Tennessee.