Thermal Spray Coating Market

Global Thermal Spray Coating Market Research Report: By Material (Ceramics, Metal & Alloys, and Others), Process (Combustion Flame Spraying, Arc Spraying, Plasma Spraying, HVOF, and Others), End-Use Industry (Automotive, Aerospace, Healthcare, Agriculture, Industrial, and Others), and Region (North America, Europe, Asia-Pacific, and Rest of the World) Global Industry Analysis, Size, Share, Growth, Trends, Regional Analysis, Competitor Analysis and Forecast 2023-2031.

Chemical & Material | September 2023 | Report ID: EMR00191 | Pages: 217

The Global Thermal Spray Coating Market was valued at USD 9.8 billion in 2022 and is estimated to reach approximately USD 16.6 billion by 2031, at a CAGR of 6.0% from 2023 to 2031. Thermal spray coating is a surface modification process used to apply protective or functional coatings onto a variety of substrates. It involves heating and propelling coating materials, typically in the form of powders or wires, onto the substrate's surface. The impact of these particles creates a strong mechanical bond between the coating material and the substrate, resulting in improved surface properties. The primary purpose of thermal spray coatings is to enhance the substrate's performance in terms of wear resistance, corrosion protection, thermal insulation, electrical conductivity, and other functional or decorative attributes. This process is widely used across industries such as aerospace, automotive, energy, manufacturing, and more. The market has been characterized by continuous innovation and technological advancements. Various techniques, including flame spraying, arc spraying, plasma spraying, and HVOF (High-Velocity Oxygen Fuel) spraying, have been developed to accommodate different coating materials and substrate types. These innovations have broadened the range of potential applications and contributed to the growing significance of thermal spray coatings in additive manufacturing and 3D printing processes. In an era where industries demand heightened durability, performance, and longevity from their components and structures, the thermal spray coating market stands as an essential enabler of these attributes. Its capacity to engineer surfaces with tailored properties continues to shape the evolution of multiple sectors, ensuring that materials can withstand the demands of modern applications while advancing the boundaries of technological innovation.




Report Attribute


Estimated Market Value (2022)

9.8 Bn

Projected Market Value (2031)

16.6 Bn

Base Year


Forecast Years

2023 - 2031

Scope of the Report

Historical and Forecast Trends, Industry Drivers and Constraints, Historical and Forecast Market Analysis by Segment- By Material, By Process, By End-Use Industry, & Region

Segments Covered

By Material, By Process, By End-Use Industry, & Region

Forecast Units

Value (USD Billion or Million), and Volume (Units)

Quantitative Units

Revenue in USD million/billion and CAGR from 2023 to 2031

Regions Covered

North America, Europe, Asia Pacific, Latin America, and Middle East & Africa, and the Rest of World

Countries Covered

U.S., Canada, Mexico, U.K., Germany, France, Italy, Spain, China, India, Japan, South Korea, Brazil, Argentina, GCC Countries, and South Africa, among others

Report Coverage

Market growth drivers, restraints, opportunities, Porter’s five forces analysis, PEST analysis, value chain analysis, regulatory landscape, market attractiveness analysis by segments and region, company market share analysis, and COVID-19 impact analysis.

Delivery Format

Delivered as an attached PDF and Excel through email, according to the purchase option.


Global Thermal Spray Coating Market Dynamics

The thermal spray coating market dynamics are multifaceted and dynamic. Technological advancements continuously drive innovation in coating materials, application techniques, and equipment, expanding the market's capabilities and applications across industries. Market demand is fueled by industries seeking enhanced performance, such as aerospace, automotive, and energy, driving the need for wear-resistant, corrosion-resistant, and thermally insulating coatings. Environmental regulations push for eco-friendly solutions, influencing material development. Globalization and competitive pressures encourage companies to develop unique offerings and establish global market presence. Skilled labor availability affects coating quality, prompting investments in workforce training. Economic factors and industrial cycles influence investments and market growth.


Global Thermal Spray Coating Market Drivers

  • Technological Advancements and Innovation

Innovations have led to the development of new coating materials, including high-performance alloys, ceramics, and composites, each personalized to address specific challenges in industries ranging from aerospace to manufacturing. Moreover, the evolution of application techniques, such as plasma spraying and HVOF (High-Velocity Oxygen Fuel) spraying, has enabled precise and controlled deposition, resulting in coatings that offer exceptional wear resistance, thermal insulation, and corrosion protection. Furthermore, technological advancements have facilitated the expansion of thermal spray coatings to diverse substrates, from complex geometries to delicate components, fostering their integration into emerging fields like additive manufacturing. As industries seek to enhance the durability and performance of their products, the continuous push for innovation within the thermal spray coating market remains a pivotal driver, reshaping the boundaries of what is achievable and propelling industrial progress.


  • Industry-Specific Performance Enhancement

The thermal spray coating market's growth is significantly propelled by its ability to supply the specific performance enhancement needs of various industries. Industries such as aerospace, automotive, and energy are increasingly relying on thermal spray coatings to address challenges related to wear, corrosion, and thermal management. In the aerospace sector, where components operate under extreme conditions, thermal spray coatings provide a vital layer of protection against high temperatures, abrasion, and oxidation. Aircraft turbine blades, for instance, benefit from coatings that enhance their resilience, contributing to improved efficiency and safety. As industries continue to demand higher levels of performance and longevity from their equipment and components, the specialized attributes offered by thermal spray coatings position them as an indispensable solution for tailored and reliable performance enhancement across a spectrum of applications.



  • Environmental and Health Concerns

Traditional thermal spray techniques, such as flame spraying and arc spraying, can involve the use of materials that pose environmental risks, including hazardous chemicals and heavy metals. Additionally, these processes can release fine particles and particulate emissions into the surrounding air, potentially impacting air quality and posing health risks to operators and nearby communities. While addressing environmental and health concerns adds complexity and cost to the thermal spray coating process, it is a necessary step to ensure long-term sustainability and social responsibility.


  • Complexity of Application Process

Thermal spray techniques involve intricate and precise control of various parameters, such as particle velocity, temperature, and substrate preparation, to achieve desired coating quality and performance. This complexity can lead to challenges in consistency, repeatability, and overall coating quality, particularly when dealing with intricate geometries and varying substrate materials. The variability in coating thickness, porosity, and adhesion can result from improper parameter control, affecting the overall effectiveness of the coating. Additionally, the need for skilled operators who possess a deep understanding of the process further intensifies this restraint. The scarcity of such skilled labor can hinder the widespread adoption of thermal spray coatings and impact the consistency and reliability of the final product.



  • Rising Focus on Sustainability and Eco-Friendly Solutions

The rising emphasis on sustainability and eco-friendly solutions presents a promising opportunity for the thermal spray coating market to innovate and address environmental concerns. As industries worldwide strive to reduce their ecological footprint and comply with stringent regulations, the development of environmentally responsible thermal spray coatings gains significance. The demand for greener technologies has prompted the industry to explore alternative coating materials and application processes that minimize adverse environmental impacts. Research and development efforts are focused on creating bio-based materials and water-based formulations that reduce or eliminate the use of hazardous substances and volatile organic compounds (VOCs). These advancements align with the market's drive towards eco-friendly practices and contribute to a cleaner, safer working environment


  • Expanding Applications in Medical and Healthcare Sectors

Thermal spray coatings offer the ability to tailor surface properties to specific medical applications. Coatings can be designed to improve the compatibility of implants with human tissues, reducing the risk of rejection and improving patient outcomes. The wear resistance of medical devices can also be significantly enhanced through specialized coatings, increasing their longevity and reducing the need for frequent replacements. As advancements in medical technology continue, the demand for improved biocompatibility, wear resistance, and functionality of these devices grows, creating a niche where thermal spray coatings can play a transformative role. Furthermore, thermal spray coatings can enable the incorporation of unique functionalities into medical devices.


Global Thermal Spray Coating Market Segment Overview

By Material

Based on material, the global thermal spray coating market is divided into ceramics, metal & alloys, and others. The ceramics category dominates the market with the largest revenue share. Ceramics offer a unique combination of properties, including high-temperature resistance, wear resistance, and excellent electrical and thermal insulation. This makes them particularly well-suited for applications in extreme environments, such as aerospace, energy, and manufacturing. Where Metal and alloy coatings are versatile and widely employed in various industries. They provide enhanced wear resistance, corrosion protection, and thermal conductivity. Applications range from automotive components, where metal coatings improve engine parts' longevity, to oil and gas equipment, where they shield against harsh environmental conditions.


By Process

Based on process, the global thermal spray coating market is categorized into combustion flame spraying, arc spraying, plasma spraying, HVOF, and others. The combustion flame category leads the global thermal spray coating market with the largest revenue share. This technique involves the combustion of a fuel gas and oxygen mixture to generate a high-velocity flame. Coating materials in powder form are fed into the flame, where they melt and are propelled onto the substrate. Combustion flame spraying is used for a wide range of materials and can be applied to both metallic and non-metallic coatings. In arc spraying, an electric arc is created between two consumable wires, melting them and propelling the molten material onto the substrate. It is commonly used for applying metallic coatings and offers high deposition rates and good adhesion. Plasma spraying involves using a plasma arc to heat and melt the coating material, which is then accelerated and propelled onto the substrate. Where, HVOF spraying employs a high-velocity stream of oxygen and fuel gas to propel coating materials onto the substrate at supersonic speeds. This process produces coatings with high density, low porosity, and excellent adhesion, making it suitable for applications requiring wear and corrosion resistance.


By End-Use Industry

Based on the end-use industry, the global thermal spray coating market is segmented into automotive, aerospace, healthcare, agriculture, industrial, and others. The aerospace segment dominates the thermal spray coating market. In the aerospace industry, these coatings are extensively used to safeguard crucial components like gas turbine engine parts, aircraft structures, and aerostructures. Thermal barrier coatings (TBCs) ensure the efficiency and durability of gas turbine engines by shielding them from high temperatures, enhancing fuel efficiency, and reducing maintenance costs. Additionally, coatings on aircraft components enhance their longevity and overall operational safety, vital in an industry where reliability is paramount.


Global Thermal Spray Coating Market Overview by Region

The global thermal spray coating market is categorized into North America, Europe, Asia-Pacific, and the Rest of the World. North America emerged as the leading region, capturing approximately 6.6% of the market share during t   forecast period. North America boasts a well-developed aerospace, automotive, energy, and manufacturing industry. These sectors heavily rely on thermal spray coatings to enhance the durability, performance, and safety of components, driving significant demand. North America is a global leader in aerospace and defense. The extensive use of thermal spray coatings in these industries, particularly for gas turbine engines, contributes significantly to the region's market dominance. The presence of research institutions, coating manufacturers, and end-users fosters collaboration, enabling the development of cutting-edge coatings tailored to specific industry needs. Also, Stable economic conditions in North America facilitate investments in advanced technologies and infrastructure, allowing for increased adoption of thermal spray coatings across various sectors.



Global Thermal Spray Coating Market Competitive Landscape

In the global thermal spray coating market, a few major players exert significant market dominance and have established a strong regional presence. These leading companies remain committed to continuous research and development endeavors and actively engage in strategic growth initiatives, including product development, launches, joint ventures, and partnerships. By pursuing these strategies, these companies aim to strengthen their market position, expand their customer base, and capture a substantial share of the market.


Some of the prominent players in the global thermal spray coating market include 3M, A&A Thermal Spray Coatings, Inc., APS Materials, Inc., CoorsTek, Inc., Dupont De Nemours, Inc., Integrated Global Services, Inc., KCC Corporation (KCC), Linde Plc, Morgan Advanced Materials plc , Fosbel, Keronite Group, Oerlikon Metco,, Swain Tech Coatings, and various other key players.


Global Thermal Spray Coating Market Recent Developments

In March 2021. Oerlikon Metco Coating Services (MCS) focuses their U.S. thermal spray and laser cladding activities and joins Oerlikon AM in Huntersville, NC. As thermal spray and laser cladding capabilities are essential to Oerlikon Metco's service portfolio, the company has now committed to making a sizeable investment at this plant. The business can now provide "Print & Coat" parts because Oerlikon AM and Oerlikon Metco have combined their coating and additive manufacturing technologies under one roof.


Scope of the Global Thermal Spray Coating Market Report

Thermal Spray Coating Market Report Segmentation



By Material

  • Ceramics
  • Metal & Alloys
  • Others

By Process

  • Combustion Flame Spraying
  • Arc Spraying
  • Plasma Spraying
  • HVOF
  • Others

By End-Use Industry

  • Automotive
  • Aerospace
  • Healthcare
  • Agriculture
  • Industrial
  • Others

By Geography

  • North America (USA, and Canada)
  • Europe (UK, Germany, France, Italy, Spain, Russia and Rest of Europe)
  • Asia Pacific (Japan, China, India, Australia, Southeast Asia and Rest of Asia Pacific)
  • Latin America (Brazil, Mexico, and Rest of Latin America)
  • Middle East & Africa (South Africa, GCC, and Rest of Middle East & Africa)

Customization Scope

  • Available upon request


  • Available upon request


Objectives of the Study

The objectives of the study are summarized in 5 stages. They are as mentioned below:


  • Global Thermal Spray Coating Market Size and Forecast:

To identify and estimate the market size for the global thermal spray coating market segmented by material, by process, by end-use Industry, region, and by value (in U.S. dollars). Also, to understand the consumption/ demand created by consumers of thermal spray coating between 2019 and 2031.


  • Market Landscape and Trends:

To identify and infer the drivers, restraints, opportunities, and challenges for the global thermal spray coating market


  • Market Influencing Factors:

To find out the factors which are affecting the sales of thermal spray coating among consumers


  • Impact of COVID-19:

To identify and understand the various factors involved in the global thermal spray coating market affected by the pandemic


  • Company Profiling:

To provide a detailed insight into the major companies operating in the market. The profiling will include the financial health of the company's past 2-3 years with segmental and regional revenue breakup, product offering, recent developments, SWOT analysis, and key strategies.


Intended Audience

  • thermal spray coating Manufacturers
  • Raw Material Suppliers
  • Retailers, Wholesalers, and Distributors
  • Governments, Associations, and Industrial Bodies
  • Investors and Trade Experts

Research Methodology

Our research methodology has always been the key differentiating reason which sets us apart in comparison from the competing organizations in the industry. Our organization believes in consistency along with quality and establishing a new level with every new report we generate; our methods are acclaimed and the data/information inside the report is coveted. Our research methodology involves a combination of primary and secondary research methods. Data procurement is one of the most extensive stages in our research process. Our organization helps in assisting the clients to find the opportunities by examining the market across the globe coupled with providing economic statistics for each and every region.  The reports generated and published are based on primary & secondary research. In secondary research, we gather data for global Market through white papers, case studies, blogs, reference customers, news, articles, press releases, white papers, and research studies. We also have our paid data applications which includes hoovers, Bloomberg business week, Avention, and others.

Data Collection

Data collection is the process of gathering, measuring, and analyzing accurate and relevant data from a variety of sources to analyze market and forecast trends. Raw market data is obtained on a broad front. Data is continuously extracted and filtered to ensure only validated and authenticated sources are considered. Data is mined from a varied host of sources including secondary and primary sources.

Primary Research

After the secondary research process, we initiate the primary research phase in which we interact with companies operating within the market space. We interact with related industries to understand the factors that can drive or hamper a market. Exhaustive primary interviews are conducted. Various sources from both the supply and demand sides are interviewed to obtain qualitative and quantitative information for a report which includes suppliers, product providers, domain experts, CEOs, vice presidents, marketing & sales directors, Type & innovation directors, and related key executives from various key companies to ensure a holistic and unbiased picture of the market. 

Secondary Research

A secondary research process is conducted to identify and collect information useful for the extensive, technical, market-oriented, and comprehensive study of the market. Secondary sources include published market studies, competitive information, white papers, analyst reports, government agencies, industry and trade associations, media sources, chambers of commerce, newsletters, trade publications, magazines, Bloomberg BusinessWeek, Factiva, D&B, annual reports, company house documents, investor presentations, articles, journals, blogs, and SEC filings of companies, newspapers, and so on. We have assigned weights to these parameters and quantified their market impacts using the weighted average analysis to derive the expected market growth rate.

Top-Down Approach & Bottom-Up Approach

In the top – down approach, the Global Batteries for Solar Energy Storage Market was further divided into various segments on the basis of the percentage share of each segment. This approach helped in arriving at the market size of each segment globally. The segments market size was further broken down in the regional market size of each segment and sub-segments. The sub-segments were further broken down to country level market. The market size arrived using this approach was then crosschecked with the market size arrived by using bottom-up approach.

In the bottom-up approach, we arrived at the country market size by identifying the revenues and market shares of the key market players. The country market sizes then were added up to arrive at regional market size of the decorated apparel, which eventually added up to arrive at global market size.

This is one of the most reliable methods as the information is directly obtained from the key players in the market and is based on the primary interviews from the key opinion leaders associated with the firms considered in the research. Furthermore, the data obtained from the company sources and the primary respondents was validated through secondary sources including government publications and Bloomberg.

Market Analysis & size Estimation

Post the data mining stage, we gather our findings and analyze them, filtering out relevant insights. These are evaluated across research teams and industry experts. All this data is collected and evaluated by our analysts. The key players in the industry or markets are identified through extensive primary and secondary research. All percentage share splits, and breakdowns have been determined using secondary sources and verified through primary sources. The market size, in terms of value and volume, is determined through primary and secondary research processes, and forecasting models including the time series model, econometric model, judgmental forecasting model, the Delphi method, among Flywheel Energy Storage. Gathered information for market analysis, competitive landscape, growth trends, product development, and pricing trends is fed into the model and analyzed simultaneously.

Quality Checking & Final Review

The analysis done by the research team is further reviewed to check for the accuracy of the data provided to ensure the clients’ requirements. This approach provides essential checks and balances which facilitate the production of quality data. This Type of revision was done in two phases for the authenticity of the data and negligible errors in the report. After quality checking, the report is reviewed to look after the presentation, Type and to recheck if all the requirements of the clients were addressed.

Frequently Asked Questions

The global thermal spray coating market forecast period is 2023 - 2031
According to thermal spray coating market research, the market is expected to grow at a CAGR of ~6.0% over the coming years.
North America is expected to register the highest CAGR during 2023 - 2031
North America held the largest share in 2022
The major players operating in the global thermal spray coating market include 3M, A&A Thermal Spray Coatings, Inc., APS Materials, Inc., CoorsTek, Inc., Dupont De Nemours, Inc., Integrated Global Services, Inc., KCC Corporation (KCC), Linde Plc, Morgan Advanced Materials plc, Fosbel, Keronite Group, Oerlikon Metco,, Swain Tech Coatings, and various others.

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