Metal Matrix Composites - Global Strategic Business Report

Global Industry Analysts, Inc, March 2012, Pages: 257

This report analyzes the worldwide markets for Metal Matrix Composites in US$ Million and Thousand Pounds (lbs) by the following Product Segments: Aluminum Matrix Composites, Nickel Matrix Composites, Refractory Metal Matrix Composites, and Other Metal Matrix Composites. The report provides separate comprehensive analytics for the US, Europe, Asia-Pacific, and Rest of World. Annual estimates and forecasts are provided for the period 2009 through 2017. Also, a six-year historic analysis is provided for these markets.The report profiles 80 companies including many key and niche players such as 3A Composites, 3M Company, ADMA Products, Inc., Aerospace Metal Composites Limited, Alcoa Inc., Daewha Alloytic Co. Ltd., Ametek Specialty Metal Products, Materion Corporation, Ceradyne, Inc., CPS Technologies Corporation, DWA Aluminum Composites, Deutsche Edelstahlwerke GmbH, Electrovac AG, FMW Composite Systems, Inc., Foster-Miller, Inc., Hitachi Metals, Ltd., Metal Matrix Cast Composites LLC, MI-Tech Metals Inc., Momentive, N.V. Bekaert S.A., PLANSEE Thermal Management Solutions, Thresher Industries, Inc., and Thermal Transfer Composites LLC. Market data and analytics are derived from primary and secondary research. Company profiles are primarily based upon search engine sources in the public domain.

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METAL MATRIX COMPOSITES

A GLOBAL STRATEGIC BUSINESS REPORT

CONTENTS

I. INTRODUCTION, METHODOLOGY & PRODUCT DEFINITIONS
Study Reliability and Reporting Limitations I-1
Disclaimers I-2
Data Interpretation & Reporting Level I-3
Quantitative Techniques & Analytics I-3
Product Definitions and Scope of Study I-3
Metal Matrix Composites I-3
Aluminum Matrix Composites I-4
Nickel Matrix Composites I-4
Refractory Metal Matrix Composites I-4
Other Metal Matrix Composites I-4
Titanium Matrix Composites I-4
Copper Matrix Composites I-5

II. Executive Summary

1. MARKET OVERVIEW II-1
Market Overview II-1
Impact of the 2007-2009 Recession in Retrospect II-2
Impact of the Debt Crisis on the Market in Europe II-2
Future MMC Market Directions II-4
MMC History II-5
A Cost Sensitive Industry II-5
MMC Issues & Solutions II-5
Solutions Related to AMCs II-6
High Costs - Biggest Hurdle to MMC Growth II-6
The Players - Historic Review II-6
Table 1: Global Metal Matrix Composites Market (2006) -
Percentage Market Share of Leading Producers for Alcan
Composites, GE Advanced Ceramics, Plansee Group, Sumitomo,
Lanxide, 3M, Electrovac, and Others (includes corresponding
Graph/Chart) II-6

2. PRODUCT OVERVIEW II-7
Composite II-7
Applications II-7
Applications in Railways II-7
Matrix II-7
Reinforcement II-8
Types of Reinforcements II-8
Continuous Reinforcement II-8
Discontinuous Reinforcement II-8
Metal Matrix Composite II-8
MMC Classification II-9
Continuous MMCs II-9
Multifilament MMCs II-10
Monofilaments II-10
Discontinuous MMCs II-10
Particulate MMCs II-10
Short Fiber MMCs II-11
Whiskers II-11
Cermets II-11
Metallic Foams II-11
Layered MMCs II-12
Hybrid Metal Composites II-12
Intermetallic Matrix Composites II-12
Methods for MMC Fabrication II-12
Solid State Method II-13
Powder Metallurgy II-13
Liquid State Method II-13
Physical Vapor Deposition II-13
Aluminum Matrix Composites (AMCs) II-13
Definition II-13
Types of AMCs II-14
Continuous Fibre-Reinforced AMCs (CFAMCs) II-14
Particle Reinforced AMCs (PAMCs) II-14
Whisker- or Short Fibre-Reinforced AMCs II-14
Mono Filament Reinforced AMCs II-14
AMC Fabrication Methods II-15
Solid State Processing II-16
Powder Metallurgy II-16
Diffusion Bonding II-16
Physical Vapor Deposition (PVD) II-16
Liquid State Processing II-16
Stir Casting (Vortex Technique) II-16
Infiltration Process II-17
Spray Deposition/Direct Processing II-17
Reactive Processing (In-situ Processing) II-17
AMC Applications II-17
Applications in the Aerospace Sector II-18
Nickel Matrix Composites II-18
Refractory Metal Matrix Composites II-18
Titanium Matrix Composites II-18
TMC Applications II-19
Copper Matrix Composites II-19
Application Industries of MMCs II-19
Aerospace II-19
Pre-requisites in the Aerospace Industry II-19
Automobile II-19
Electronic Packaging II-20
Power Transmission II-20
Buildings II-20

3. PRODUCT INNOVATIONS/INTRODUCTIONS II-22
Materials Engineers at Rice University Develop New Composite
Materials II-22
Touchstone Introduces MetPreg® II-22
Thresher Industries to Develop Low-Carbon Renewable Heat Sinks
for LED Lighting Market II-22
M Cubed Launches Advanced Stiff and Light Metal Matrix Composite II-22
Sifco Develops New Process to Brush Plate Cobalt Metal Matrix
Composite II-23

4. PRODUCT INNOVATIONS/INTRODUCTIONS - A HISTORIC PERSPECTIVE BUILDER II-24
CPS Technologies Releases AlSiC Metal Matrix Pin Fin Coolers II-24
CPS Launches TO-250 Product Suite II-24
CPS Develops AlSiC Hermetic Packaging Solutions II-24
CPS Unveils AlSiC for Automation of Robotic Arms II-24
IKONICS Introduces Metal Matrix Composite II-25
Alcoa Develops Aluminum Composite Panel II-25
Polymer Nanoparticle for Metal Composite Developed in USA II-25
Aluminum Composite Material Manufactured by Japanese Individual II-25
Inventors from the US Develop Metal-Carbon Composite Powders II-25
Mesoporous Crystalline Alumina Composition Developed by
Michigan Individuals II-26
Polymer-Metal Composition Developed II-26
Hybrid Composite-Metal Seat Assembly Developed in the US II-26
Adal Group Develops New Metal Matrix Composite II-26
CPS Releases MMC for Heat Dissipating Uses II-26
CPS Releases AlSiC for High LEDs II-27
Vykor Offers Composite Materials Solutions II-27
Resin-Metal Composite Developed II-27
Spain Research Team Develops Metal Matrix Composites II-27

5. STRATEGIC CORPORATE DEVELOPMENTS II-28
Thresher Industries Inks Marketing Partnership Deal with AFT II-28
Edelstahl Witten-Krefeld Merges Operations with Edelstahlwerke
Südwestfalen II-28
Thresher Acquires Talon Composites II-28
Thresher Establishes Manufacturing Facility in South Korea II-28
CTC Inks Agreement with Far East Composite Technology Company II-28
GKN and FMW Bag TMMC Contract from Boeing II-29
MMCC Wins Product Development Contract from Army Research
Laboratory II-29
Apollo Acquires GE Advanced Materials II-29
IKONICS and Roland Sign Distribution Agreement II-29
Ceradyne and Alcan Enter into Joint Production and Supply
Agreement II-30
CPS Sub-Contracts With 3M in Army Contract II-30
Rogers Corp Partners with Thermal Transfer Composites II-30
Durabuild Expands Aluminum Composite Unit's Capacity II-31
Hampson Industries Takes Over Coast Composites II-31
EDO Corp Adds Fiber Innovations II-31
LDI Composites Acquires Kadant's Business II-31
Owens Corning Expands With Asahi Glass' Acquisition in Asia-
Pacific II-31
FMW Bags US Navy Contract II-31
TAI Completes Composite Manufacturing Contract II-32
Talon and BNFL Extend Alliance II-32
MMCC and California University Join Forces for Aluminum
Magnesium Matrix Composite II-32
Talon Collaborates with J. E. Access II-32
Solidica Joins Hands with the US Army II-33
Cymat Obtains Patent for MMC Process in the US II-33

6. FOCUS ON SELECT GLOBAL PLAYERS II-34
3A Composites (Switzerland) II-34
3M Company (USA) II-34
ADMA Products, Inc. (USA) II-34
Aerospace Metal Composites Limited (UK) II-35
Alcoa Inc (USA) II-35
Daewha Alloytic Co. Ltd. (Korea) II-36
Ametek Specialty Metal Products (USA) II-36
Materion Corporation (USA) II-36
Ceradyne, Inc (USA) II-36
CPS Technologies Corporation (USA) II-37
DWA Aluminum Composites (USA) II-37
Deutsche Edelstahlwerke GmbH (Germany) II-38
Electrovac AG (Austria) II-38
FMW Composite Systems, Inc. (USA) II-38
Foster-Miller, Inc. (USA) II-39
Hitachi Metals, Ltd (Japan) II-39
Metal Matrix Cast Composites LLC (USA) II-39
MI-Tech Metals Inc (USA) II-40
Momentive (USA) II-40
N.V. Bekaert S.A. (Belgium) II-41
PLANSEE Thermal Management Solutions (USA) II-41
Thresher Industries, Inc. (USA) II-41
Thermal Transfer Composites LLC (USA) II-42

7. GLOBAL MARKET PERSPECTIVE II-43
Table 2: World Recent Past, Current & Future Market Analysis
for Metal Matrix Composites by Geographic Region - US, Europe,
Asia-Pacific (Including Japan), and Rest of World
Independently Analyzed with Annual Sales in US$ Million for
Years 2009 through 2017 (includes corresponding Graph/Chart) II-43

Table 3: World Historic Review for Metal Matrix Composites by
Geographic Region - US, Europe, Asia-Pacific (Including
Japan), and Rest of World Independently Analyzed with Annual
Sales in US$ Million for Years 2003 through 2008 (includes
corresponding Graph/Chart) II-44

Table 4: World 15-Year Perspective for Metal Matrix Composites
by Geographic Region - Percentage Breakdown of Dollar Sales
for US, Europe, Asia-Pacific (Including Japan), and Rest of
World Markets for 2003, 2011 & 2017 (includes corresponding
Graph/Chart) II-45
Product Segment Analytics II-46
Table 5: World Recent Past, Current & Future Market Analysis
for Metal Matrix Composites by Product Segment - Aluminum
Matrix Composites, Nickel Matrix Composites, Refractory Metal
Matrix Composites, and Other Metal Matrix Composites*
Independently Analyzed with Annual Sales in US$ Million for
Years 2009 through 2017 (includes corresponding Graph/Chart) II-46

Table 6: World Historic Review for Metal Matrix Composites by
Product Segment - Aluminum Matrix Composites, Nickel Matrix
Composites, Refractory Metal Matrix Composites, and Other
Metal Matrix Composites* Independently Analyzed with Annual
Sales in US$ Million for Years 2003 through 2008 (includes
corresponding Graph/Chart) II-47

Table 7: World 15-Year Perspective for Metal Matrix Composites
by Product Segment - Percentage Breakdown of Dollar Sales for
Aluminum Matrix Composites, Nickel Matrix Composites,
Refractory Metal Matrix Composites, and Other Metal Matrix
Composites* for 2003, 2011 & 2017 (includes corresponding
Graph/Chart) II-48
Analytics by End-Use Industry II-49
Table 8: World Recent Past, Current & Future Market Analysis
for Metal Matrix Composites by End-Use Industry - Ground
Transportation, Electronics/ Thermal Management, Aerospace,
Industrial and Other* Markets Independently Analyzed with
Annual Sales in ‘000 lbs for Years 2009 through 2017 (includes
corresponding Graph/Chart) II-49

Table 9: World Historic Review for Metal Matrix Composites by
End-Use Industry - Ground Transportation, Electronics/Thermal
Management, Aerospace, Industrial and Other* Markets
Independently Analyzed with Annual Sales in ‘000 lbs for Years
2003 through 2008 (includes corresponding Graph/Chart) II-50

Table 10: World 15-Year Perspective for Metal Matrix
Composites by End-Use Industry - Percentage Breakdown of
Volume Sales for Ground Transportation, Electronics/Thermal
Management, Aerospace, Industrial and Other Markets for 2003,
2011 & 2017 (includes corresponding Graph/Chart) II-51
Industrial Metal Matrix Composites Market II-52
Table 11: World Recent Past, Current & Future Market Analysis
for Industrial Metal Matrix Composites by Application -
Thermal Processing, Nuclear, Power Transmission, and Other*
Markets Independently Analyzed with Annual Sales in ‘000 lbs
for Years 2009 through 2017 (includes corresponding
Graph/Chart) II-52

Table 12: World Historic Review for Industrial Metal Matrix
Composites by Application - Thermal Processing, Nuclear, Power
Transmission, and Other Markets Independently Analyzed with
Annual Sales in ‘000 lbs for Years 2003 through 2008 (includes
corresponding Graph/Chart) II-53

Table 13: World 15-Year Perspective for Industrial Metal
Matrix Composites by Application - Percentage Breakdown of
Volume Sales for Thermal Processing, Nuclear, Power
Transmission and Other Markets for 2003, 2011 & 2017 (includes
corresponding Graph/Chart) II-54

Table 14: World Recent Past, Current & Future Market Analysis
for Industrial Metal Matrix Composites by Application -
Thermal Processing, Nuclear, Power Transmission, and Other
Markets Independently Analyzed with Annual Sales in US$
Million for Years 2009 through 2017 (includes corresponding
Graph/Chart) II-55

Table 15: World Historic Review for Industrial Metal Matrix
Composites by Application - Thermal Processing, Nuclear, Power
Transmission, and Other Markets Independently Analyzed with
Annual Sales in US$ Million for Years 2003 through 2008
(includes corresponding Graph/Chart) II-56

Table 16: World 15-Year Perspective for Industrial Metal
Matrix Composites by Application - Percentage Breakdown of
Value Sales for Thermal Processing, Nuclear, Power
Transmission, and Other Markets for 2003, 2011 & 2017
(includes corresponding Graph/Chart) II-57

III. MARKET

1. THE UNITED STATES III-1
A.Market Analysis III-1
Market Overview III-1
B.Market Analytics III-1
Table 17: US Recent Past, Current & Future Market Analysis
for Metal Matrix Composites Analyzed with Annual Sales
Figures in US$ Million for Years 2009 through 2017 (includes
corresponding Graph/Chart) III-1

Table 18: US Historic Review for Metal Matrix Composites
Analyzed with Annual Sales Figures in US$ Million for Years
2003 through 2008 (includes corresponding Graph/Chart) III-2

2. EUROPE III-3
A.Market Analysis III-3
Composite Industry in the UK III-3
B.Market Analytics III-4
Table 19: European Recent Past, Current & Future Market
Analysis for Metal Matrix Composites by Geographic Region -
France, Germany, Italy, UK & Rest of Europe Markets
Independently Analyzed with Annual Sales Figures in US$
Million for Years 2009 Through 2017 (includes corresponding
Graph/Chart) III-4

Table 20: European Historic Review for Metal Matrix
Composites by Geographic Region - France, Germany, Italy, UK
& Rest of Europe Markets Independently Analyzed with Annual
Sales Figures US$ Million for Years 2003 through 2008
(includes corresponding Graph/Chart) III-5

Table 21: European 15-Year Perspective for Metal Matrix
Composites by Geographic Region - Percentage Breakdown of
Dollar Sales for France, Germany, Italy, UK & Rest of Europe
Markets for Years 2003, 2011 & 2017 (includes corresponding
Graph/Chart) III-6

3. ASIA-PACIFIC III-7
A.Market Analysis III-7
India - Composites in Indian Railways III-7
B.Market Analytics III-7
Table 22: Asia-Pacific Recent Past, Current & Future Market
Analysis for Metal Matrix Composites Analyzed with Annual
Sales Figures in US$ Million for Years 2009 through 2017
(includes corresponding Graph/Chart) III-7

Table 23: Asia-Pacific Historic Review for Metal Matrix
Composites Analyzed with Annual Sales Figures in US$ Million
for Years 2003 through 2008 (includes corresponding
Graph/Chart) III-8

4. REST OF WORLD III-9
Market Analytics III-9
Table 24: Rest of World Recent Past, Current & Future Market
Analysis for Metal Matrix Composites Analyzed with Annual
Sales Figures in US$ Million for Years 2009 through 2017
(includes corresponding Graph/Chart) III-9

Table 25: Rest of World Historic Review for Metal Matrix
Composites Analyzed with Annual Sales Figures in US$ Million
for Years 2003 through 2008 (includes corresponding
Graph/Chart) III-10

IV. COMPETITIVE LANDSCAPE

Total Companies Profiled: 80 (including Divisions/Subsidiaries - 81)

------------------------------------------
Region/Country Players
------------------------------------------
The United States 54
Canada 6
Japan 4
Europe 15
Germany 1
The United Kingdom 7
Rest of Europe 7
Asia-Pacific (Excluding Japan) 2
------------------------------------------

As constructional and functional materials capable of meeting desired material standards and specifications, Metal Matrix Composites find ubiquitous uses in a wide range of industries. Opportunities in this market remain as broad as the unlimited possibilities these innovative materials open up in the field of modern material science. The infinite combination of various material systems offers the potential for unlimited variations. In the automobile industry, MMCs has and will continue to be driven by the growing demand for lighter and fuel efficient vehicles. MMCs are emerging as a viable alternative to facilitate the production of lighter vehicles. The market in the upcoming years is forecast to witness increased investments in research & development, especially in the field of light metal matrix composites. In the microprocessor industry, MMCs are used to meet the heat generation challenges posed by increasing performance of microprocessors.

The nuclear power equipment industry also promises ample opportunities for growth. Increasing demand for energy, rising prices of fossil fuels, need for cheaper, inexpensive power, juxtaposed with the growing adoption of nuclear power by countries worldwide, indirectly presents business opportunities for MMCs in the manufacturing of nuclear reactor components. The scale of opportunities can be put into perspective by the fact that over 60 new reactors are scheduled to commence commercial operations between 2010 and 2020, while an additional 70 reactors are in various planning stages in developing countries. In the power transmission industry, growing population, spiraling demand for energy, investment in power utility infrastructure will continue to support growth of power transmission systems. Also, since storage of electricity is an expensive proposition, electric power produced is delivered almost simultaneously, and this directly translates into the need for highly efficient transmission and distribution equipment. MMCs, as materials with tailored properties, are therefore forecast to witness healthy demand in the manufacture of power transmission housings, cables, electric conductors and lines. Steady growth in the electronics and semiconductors industry also bodes well for the use of MMCs in thermal management applications such as in power conversion and electronic packaging applications.

While all key end-use industries are recovering from the 2007-2009 recession, the industries in Europe are running into a fresh set of challenges. The semiconductor, electronics, automotive, and industrial equipment industries currently remain nervous over the play out of the debt crisis that currently hangs over Western Europe. Macro themes affecting Europe include the prolonging of the sovereign debt crisis as a result of the half-measures implemented till date in attempts to stave off the crisis, a dysfunctional financial system that is fuelling a slow-motion economic collapse and fears over reduced consumer spending and slower economic growth as a result of austerity measures. At the extreme pessimistic end of the spectrum, bearish outlook indicates a possible collapse of the Euro as a common currency, which could pose insurmountable problems for the MMC market. Under such a scenario, higher inflation, credit restrictions, and capital shortages as a result of austerity measures, higher unemployment and reduced consumer spending could spiral out of control, significantly denting market prospects. A more balanced outlook is the possible exit of the debt ridden economies, Portugal, Italy, Ireland, Greece and Spain, from the European Union. A return to local currencies, which would be massively devalued, will also bring in critical implications for the market.

In the automobile industry in the region, immediate production cutbacks are not seen as likely, given the yet patchy slowdown in auto sales. For instance, there pockets of strength continue to exist in the region, such as in Germany and the UK alongside the quarterly weakness witnessed in France, Spain and Portugal. Production continues to hold up even in the face of weaker than expected growth and optimism remains with no downgrade in the outlook for auto production. Manufacturing activities, engineering activities, and industrial production, which continued to recover from 2010 through 2011 is expected to continue into the year 2012. For instance, in Germany, industrial and manufacturing output is holding up well as indicated by the country’s yet strong export market, a key reason for the country’s superior handling of its debt crisis in comparison with Greece, Portugal, Spain and Italy. Given the yet unclear signs of a possible decline in industrial production in Europe, factory investments will continue into the immediate future. The yet healthy sales of consumer electronics, flat-screen TVs, laptops, and smartphones, witnessed during the holding season in December 2011, additionally indicates that consumer confidence is holding up. Also, the influx of overseas shoppers, as result of the Euro depreciation, has also benefited retail sales. Against the backdrop of all of these factors, consumer spending which continues to remain a key pillar of growth across all the end-use markets is expected to hold up in the year 2012, and yet another cycle of downturn is currently not seen as likely for the MMC market.

As stated by the new market research report on Metal Matrix Composites, United States remains the largest market worldwide. Asia-Pacific is expected to emerge into the fastest growing regional market with a projected CAGR of 6.9% over the analysis period.

Global Industry Analysts ©

Sample list of companies:

- 3A Composites (Switzerland)
- 3M Company (USA)
- ADMA Products, Inc. (USA)
- Aerospace Metal Composites Limited (UK)
- Alcoa Inc (USA)
- Alloytic Co. Ltd. (Korea)
- Ametek Specialty Metal Products (USA)
- Brush Engineered Materials Inc (USA)
- Ceradyne, Inc (USA)
- CPS Technologies Corporation (USA)
- Composite Technology Corporation (USA)
- DWA Aluminum Composites (USA)
- Deutsche Edelstahlwerke GmbH (Germany)
- Electrovac AG (Austria)
- FMW Composite Systems, Inc. (USA)
- Foster-Miller, Inc. (USA)
- Hitachi Metals, Ltd (Japan)
- Metal Matrix Cast Composites LLC (USA)
- MI-Tech Metals Inc (USA)
- Momentive Performance Materials Inc. (USA)
- N.V. Bekaert S.A. (Belgium)
- PLANSEE Thermal Management Solutions (USA)
- Thresher Industries, Inc. (USA)
- Thermal Transfer Composites LLC (USA)

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