Global Thermal Spray Coatings Industry: Information By Material (Metals, Ceramics, Intermetallics, Polymers, Carbides, Abradables, Others), By Application (Aerospace, Industrial Gas, Turbine, Automotive, Medical, Printing, Oil & Gas, Steel, Pulp & Paper, Others), and  By Technology (Cold Spray, Flame Spray, Plasma Spray, HVOF, Electric Arc Spray, Others), Global Economy Insights, Regional Outlook, Growth Potential, Price Trends, Competitive Market Share , Regions & Forecast till 2031

Region: Global | Format: Word, PPT, Excel | Report Status: Published

Market Overview

Global Thermal Spray Coatings Market size was valued at USD 10.25 Billion in 2022 and is projected to reach USD 17.1 Billion by 2031, growing at a CAGR of 7.12% during the forecast period (2023-2031) according to a new report by IMIR Market Research.

Thermal spray coatings, also known as thermal spraying or spray metallization, is a surface modification process in which a material is melted or heated and then propelled onto a substrate to form a protective or functional coating. This process typically involves heating the coating material, such as metals, ceramics, or polymers, to a molten or semi-molten state. The molten particles are then accelerated and sprayed onto the surface of the substrate, where they solidify and form a coating layer. Thermal spray coatings are applied to improve surface properties such as wear resistance, corrosion resistance, thermal insulation, electrical conductivity, and more. This technique is widely used in industries such as aerospace, automotive, energy, and manufacturing.

The increasing usage of thermal spray coating technology in the automotive, aircraft, and heavy machinery industries, as well as the military and civil airliner industries, has resulted in a rise in the use of thermal spray coating technology. Thermal spray coating is used in automotive applications to cover piston and synchronizer rings. Similarly, thermal spray coating is utilised in aircraft to cover and protect engine turbine blades against severe temperatures. Increases in consumer disposable income and spending power, as well as improvements in living standards in developing countries such as China and India, drive up demand for automobiles. According to the International Organisation of Motor Vehicle Manufacturers (OICA), the rate of car manufacturing production increased by 8% in 2018 over 2017. High-performance ceramic coatings are used on automotive engine components to improve fuel efficiency.

The Thermal Spray Coatings market research report comprises a thorough examination of the current and future scenario of this industry vertical. The research highlights major trends and opportunities, as well as challenges, for various segments and sub-segments, while broadening the company horizon. The study report also includes extensive information based on past and present patterns across several industry verticals to help find various expansion prospects. Throughout the forecast period, several estimations regarding market share, market size, and industry growth rate are presented. The research includes information on competitive analysis as well as consumption habits and pricing strategies depending on the Thermal Spray Coatings market.


The Global Thermal Spray Coatings Industry Drivers:

Growing demand for thermal spray coating over hard chromium plating across various industries

Growing environmental concerns, stringent regulations governing the chrome plating process and the disposal of its byproducts, and rising costs are driving up demand for thermal spray coatings.  As a result, it has become critical for the industry to develop alternative techniques that produce hard chrome plating with comparable properties but without the associated dangers. Thermal spraying technology is gradually becoming a viable alternative to this approach, with the potential to provide complementary methods for component safety and reclamation to the chrome plating sector. Thermal coatings last far longer than chrome plating.

Thermal coatings have a substantially higher fatigue resistance than chrome plating. Because high-velocity oxygen fuel (HVOF) coatings apply a compressive load on the substrate, component life is extended by resisting fracture start against fatigue failure. Chrome plating provides tensile pressure onto the substratum's surface, causing crack formation and possibly premature failure. End-user industries shifting from chrome plating to thermal spraying are projected to drive market growth.


The Global Thermal Spray Coatings Industry Restraint:

High initial investment required and a scarcity of trained operators

The expense of the spraying technique is a major impediment to the growth of the thermal spray coatings market. Thermal coatings are applied using machines that are designed to preserve optimal coating properties. They do, however, demand periodic setups and alterations, which significantly increase maintenance and overall operation costs and are predicted to stymie market revenue growth. Furthermore, the employment of a professional operator is required for this coating method. As a result, the scarcity of skilled operators acts as an additional impediment to market revenue growth. Furthermore, a lot of fumes and dust are emitted during the thermal coating process, which has a detrimental influence on the environment and is projected to limit market revenue growth.


The Global Thermal Spray Coatings Industry Opportunities:

Rapidly Expanding Aerospace and Defense Sectors

Thermal spray coatings are widely utilised as protective coatings in the aerospace industry to maintain aircraft components and repair old ones. Thermal sprays are generally used in jet engine components such as crankshafts, piston rings, cylinders, valves, and so on. They are also used in the coating of landing gear (bearings and axles inside the landing gear) to withstand forces during landing and take-off.The United States provided USD 89.1 billion in aerospace exports in 2021, making it the leading country in the industry. The country is home to some of the world's largest aircraft manufacturers, including Boeing and Lockheed Martin. By 2021, six of the top twelve aerospace and defence companies will have.


Scope of Thermal Spray Coatings Market Report:

A recent market research report added to repository of Intellectual Market Insights Research is an in-depth analysis of Global Thermal Spray Coatings Market. On the basis of historic growth analysis and current scenario of Thermal Spray Coatings market place, the report intends to offer actionable insights on global market growth projections. Authenticated data presented in report is based on findings of extensive primary and secondary research. Insights drawn from data serve as excellent tools that facilitate deeper understanding of multiple aspects of global Thermal Spray Coatings market. This further helps users with their developmental strategy.

This report examines all the key factors influencing growth of global Thermal Spray Coatings market, including demand-supply scenario, pricing structure, profit margins, production and value chain analysis. Regional assessment of global Thermal Spray Coatings market unlocks a plethora of untapped opportunities in regional and domestic market places. Detailed company profiling enables users to evaluate company shares analysis, emerging product lines, pricing strategies, innovation possibilities and much more.

The report covers the all the aspects of industry with dedicated study of key players that includes market leaders, followers and new entrants by region. PORTER, SVOR, PESTEL analysis with the potential impact of micro-economic factors by region on the market have been presented in the report. External as well as internal factors that are supposed to affect the business positively or negatively have been analyzed, which will give clear futuristic view of the industry to the decision makers.


Thermal Spray Coatings Market Players Analysis:

  • Praxair Surface Technologies, Inc.
  • Oerlikon Group
  • H.C. Starck Surface Technology & Ceramic Powders GmbH
  • Saint-Gobain S.A.
  • Sulzer Ltd.
  • Flame Spray SpA
  • Bodycote plc
  • Arc Spray (PTY) Ltd.
  • ASB Industries, Inc.
  • Plasma Powders & Systems, Inc.
  • Metallisation Ltd.
  • A&A Coatings
  • Thermion Inc.
  • TWI Ltd.
  • Abakan Inc.
  • And More
Thermal Spray Coatings Market Players & Competitor Analysis:

The report covers the key players of the industry including Company Profile, Product Specifications, Production Capacity/Sales, Revenue, Price and Gross Margin 2023-2031 & Sales with a thorough analysis of the market’s competitive landscape and detailed information on vendors and comprehensive details of factors that will challenge the growth of major market vendors.

Recent Developments:
  • September 2020, Praxair Surface Technologies Collaborates with GE Additive - Praxair Surface Technologies, a subsidiary of Linde plc, collaborated with GE Additive to develop new metal powder solutions for additive manufacturing applications. The collaboration aimed to enhance the quality and performance of 3D-printed components using thermal spray coatings.
  • July 2020, Bodycote Acquires Ellison Surface Technologies - Bodycote, a leading provider of thermal processing services, announced the acquisition of Ellison Surface Technologies. This acquisition allowed Bodycote to expand its thermal spray coatings capabilities and strengthen its position in the aerospace, defense, and energy sectors.
  • March 2020,C. Starck Surface Technology & Ceramic Powders GmbH Launches New Thermal Spray Coating Solutions - H.C. Starck Surface Technology & Ceramic Powders GmbH, a global leader in surface technology, introduced new thermal spray coating solutions for a wide range of applications, including corrosion protection, wear resistance, and thermal insulation.
  • February 2020, Sulzer Acquires Alba Power - Sulzer, a leading provider of maintenance and repair services, acquired Alba Power, a specialist in gas turbine repair and maintenance. This acquisition expanded Sulzer's capabilities in the energy industry, including the application of thermal spray coatings for turbine components.


Thermal Spray Coatings Market Segmentation Analysis:

The global Thermal Spray Coatings industry is segmented into three categories: By Material, By Application, By Technology

Based on the Material

The Thermal Spray Coatings market is bifurcated into Metals, Ceramics, Intermetallics, Polymers, Carbides, Abradables, Others

 Because of the expanding use of ceramic, particularly in the biomedical industry, the ceramic segment represented a significant revenue share of the market. This is expected to have a favourable effect on Cookies are used to improve your experience. Because of increased demand from manufacturing, automotive, and aerospace applications.

Ceramics are in high demand because to features such as heat resistance and corrosion resistance. Furthermore, ceramics are inexpensive, which is anticipated to increase demand for this material. Metal and alloys, as well as polymers, are widely employed on the surface of the substrate, ensuring that the goods have a longer service life under rigorous working circumstances. Such metal materials can be employed to create coatings profitable due to their range of microstructures, film deposition speed, and raw material applicability. Intermetallic materials are extensively used in steam generators, coal-fired gas turbines, and other applications due to properties such as high melting point, low density, high thermal conductivity, and hot corrosion resistance. Polymers are gaining popularity in the automotive, petrochemical, aerospace, and defence industries. The polymer is used.

Based on the Application

The global Thermal Spray Coatings market is split into Aerospace, Industrial Gas, Turbine, Automotive, Medical, Printing, Oil & Gas, Steel, Pulp & Paper, Others.

The aerospace application category led the global market, accounting for the majority of revenue. Parts in an aeroplane can deteriorate due to particle erosion, hot corrosion, metal-to-metal wear, and fretting. According to a Deloitte analysis issued in 2021, many aerospace manufacturers are looking for new aftermarket services revenue prospects because to the pandemic's influence on client demand and pricing pressure. This is projected to enhance MRO work, perhaps increasing demand for thermal spray coatings in aerospace applications.

Because of the growing environmental difficulties caused by coal-fired power plants, the global focus on decarbonization is increasing. This has prompted numerous companies to focus on developing power generation methods in order to attain carbon-free power generation. Mitsubishi Power, a part of the Mitsubishi Heavy Industries (MHI) Group, for example, commenced building of a 40-megawatt (MW) class gas turbine fueled exclusively by ammonia (NH3) in March 2021. Because ammonia does not emit carbon dioxide (CO2), it may encourage power generation businesses to use industrial gas turbines for power generation, hence increasing demand for thermal spray coatings.

Based on the Technology

The global Thermal Spray Coatings market is split into Cold Spray, Flame Spray, Plasma Spray, HVOF, Electric Arc Spray, Others

The global market was controlled by plasma spray technology. This method has the benefit of spraying metallic and ceramic materials onto a range of surfaces with great binding strength while minimising substrate distortion on both big and small components. It gives the substrate surface electrical conductivity, clearance control, wear resistance, and heat and oxidation resistance. Printing rolls, gas turbines, industrial diesel engine piston rings and oil and gas gear all benefit from plasma thermal spray coatings.

Following then, High-Velocity Oxy-Fuel (HVOF) became the dominant technology in the global market. It is used to restore or improve the qualities or geometry of a component, allowing the equipment's life to be extended. The benefits of HVOF over other technologies, such as smaller porosity due to higher particle impact velocities, higher binding strength to the underlying substrate, lower oxide content, smooth surface, superior wear resistance, and improved corrosion resistance, drive market growth. HVOF sprayed coatings, on the other hand, can be exceedingly complicated because their characteristics and microstructure are dependent on multiple processing variables. Furthermore, the particle sizes are limited to roughly 5 - 60m, limiting its application even further.

Report Scope and Segmentations:

  Study Period


Base Year


Estimated Forecast Year


Growth Rate

        CAGR of 7.12% from 2023 to 2031


        By Material, By Application, By Technology, By region.


        USD Billion

By Material

  • Metals
  • Ceramics
  • Intermetallics
  • Polymers
  • Carbides
  • Abradables
  • Others

By Application

  • Aerospace
  • Industrial Gas Turbine
  • Automotive
  • Medical
  • Printing
  • Oil & Gas
  • Steel
  • Pulp & Paper
  • Others

By Technology

  • Cold Spray
  • Flame Spray
  • Plasma Spray
  • HVOF
  • Electric Arc Spray
  • Others

By Region

  • North America (U.S., Canada, Mexico)
  • Europe (Germany, France, UK, Italy, Spain, Russia, Rest of Europe)
  • Asia-Pacific (China, India, Japan, ASEAN, Rest of Asia-Pacific)
  • LAMEA (Latin America, Middle East, Africa)


Global Thermal Spray Coatings Market Regional Analysis:

The global Thermal Spray Coatings market is analyzed on the basis of region across North America, Europe, Asia-Pacific, and LAMEA.

North America controlled the global market and generated the most income. Thermal spray coatings demand in North America is primarily driven by high demand from key industries such as aerospace, oil and gas, automotive, medical, and power generation. Furthermore, governments in the United States and Canada are sponsoring studies to produce new coatings that can serve as a catalyst for market growth. For example, the Government of Canada announced in February 2022 that it would provide USD 18.92 million (CAD 24 million) through the New Frontiers in Research Fund for a project to develop unique molecular coatings that could reduce maintenance costs in sectors such as healthcare, infrastructure, automotive, aerospace, and consumer electronics.

The Asia Pacific aerospace sector is gaining traction as major aircraft manufacturers such as Airbus establish manufacturing operations in the region and source aircraft components from regional Indian firms such as the Tata Group, Dynamatic Technologies, and Mahindra Group Companies. Because automotive components subjected to harsh pressures and temperatures have a high need for thermal spray coatings, this can accelerate market expansion in the region. The Middle East and Africa region produces the most oil in the globe. The presence of major oil-producing countries like Saudi Arabia, Kuwait, Oman, Bahrain, Libya, Iraq, Angola, and Iran is likely to drive up product demand in the region's oil and gas industry.

Brazil is a leading industrial jet manufacturer, as well as a manufacturer of a variety of aerospace products, including military aircraft, turboprop aircraft, recreational aircraft, helicopters, agricultural aircraft, and various general aviation aircraft. Demand is likely to rise as thermal spray applications expand in the aerospace industry.

Furthermore, the improving healthcare sector, particularly in GCC countries, is expected to increase demand for medical devices, creating lucrative growth possibilities for the regional market for thermal spray coatings. According to the Saudi National Committee for Steel sector, the steel sector is the primary driver of Saudi Arabia's non-oil contribution to the Saudi economy. In addition, the government is establishing special economic zones to entice international corporations to establish industrial bases in the country and contribute to the non-oil economy, which will help to propel the burgeoning steel sector and positively impact the market for thermal spray coatings.

North America accounted for the highest xx% market share in terms of revenue in the Thermal Spray Coatings market and is expected to expand at a CAGR of xx% during the forecast period. This growth can be attributed to the growing adoption of Thermal Spray Coatings. The market in APAC is expected to witness significant growth and is expected to register a CAGR of xx% over upcoming years, because of the presence of key Thermal Spray Coatings companies in economies such as Japan and China.

The objective of the report is to present comprehensive analysis of Global Thermal Spray Coatings Market including all the stakeholders of the industry. The past and current status of the industry with forecasted market size and trends are presented in the report with the analysis of complicated data in simple language.

Thermal Spray Coatings Market Report is also available for below Regions and Country Please Ask for that

North America

  • U.S.
  • Canada


  • Switzerland
  • Belgium
  • Germany
  • France
  • U.K.
  • Italy
  • Spain
  • Sweden
  • Netherland
  • Turkey
  • Rest of Europe


  • India
  • Australia
  • Philippines
  • Singapore
  • South Korea
  • Japan
  • China
  • Malaysia
  • Thailand
  • Indonesia
  • Rest Of APAC

Latin America

  • Mexico
  • Argentina
  • Peru
  • Colombia
  • Brazil
  • Rest of South America

Middle East and Africa

  • Saudi Arabia
  • UAE
  • Egypt
  • South Africa
  • Rest Of MEA


Points Covered in the Report:

The points that are discussed within the report are the major market players that are involved in the market such as market players, raw material suppliers, equipment suppliers, end users, traders, distributors and etc.

The complete profile of the companies is mentioned. And the capacity, production, price, revenue, cost, gross, gross margin, sales volume, sales revenue, consumption, growth rate, import, export, supply, future strategies, and the technological developments that they are making are also included within the report. This report analysed 12 years data history and forecast.

The growth factors of the market are discussed in detail wherein the different end users of the market are explained in detail.

Data and information by market player, by region, by type, by application and etc., and custom research can be added according to specific requirements.

The report contains the SWOT analysis of the market. Finally, the report contains the conclusion part where the opinions of the industrial experts are included.

Key Reasons to Purchase:

To gain insightful analyses of the Thermal Spray Coatings market and have comprehensive understanding of the global market and its commercial landscape.

Assess the production processes, major issues, and solutions to mitigate the development risk.

To understand the most affecting driving and restraining forces in the market and its impact in the global market.

Learn about the Thermal Spray Coatings market strategies that are being adopted by leading respective organizations.

To understand the future outlook and prospects for the Thermal Spray Coatings market. Besides the standard structure reports, we also provide custom research according to specific requirements.

Research Scope of Thermal Spray Coatings Market:

  • Historic year: 2018- 2021
  • Base year: 2022
  • Forecast: 2023 to 2031
  • Representation of Market revenue in USD Million

Thermal Spray Coatings Market Trends: Market key trends which include Increased Competition and Continuous Innovations Trends
  • PUBLISHED ON : June, 2022
  • BASE YEAR : 2023
  • STUDY PERIOD : 2020-2032
  • NO OF PAGES : 380

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