| Study Period | 2019 - 2030 |
| Base Year For Estimation | 2024 |
| Forecast Data Period | 2025 - 2030 |
| CAGR | 6.00 % |
| Fastest Growing Market | Asia Pacific |
| Largest Market | North America |
| Market Concentration | Low |
Major Players
*Disclaimer: Major Players sorted in no particular order |
Thermal Spray Coatings Market Analysis
The Thermal Spray Coatings Market is expected to register a CAGR of greater than 6% during the forecast period.
In 2020, COVID-19 severely impacted industry growth due to decreased aircraft production and raw materials shortage. However, the growing aerospace industry post-pandemic is expected to increase thermal spray coatings consumption.
- The extensive usage of thermal spray coatings in the aerospace sector increased usage in medical devices, and the rising popularity of thermal spray ceramic coatings primarily drives the market's growth.
- Stringent government regulations for thermal spray coatings and issues regarding process reliability and consistency will likely restrain the market growth.
- The increasing applications in the oil and gas industry, advancements in spraying technology, and recycling of thermal spray processing materials are expected to provide numerous opportunities for the manufacturers in the market studied.
- North America dominated the global spray coatings market due to increased application in the aerospace industry and medical devices.
Thermal Spray Coatings Market Trends
Increasing Demand from the Aerospace Industry
- In the aerospace sector, thermal spray coatings are extensively used as protective coatings to protect aircraft components and repair old ones. The usage of thermal spray coatings for aircraft gas turbines provides various advantages, such as better corrosion resistance, resistance from contaminants, improved thermal efficiency, reduced emissions of nitrogen oxide (NOX), actuation systems, and to provide high thermal resistance, and increased component life.
- Thermal sprays are primarily employed for various purposes in jet engine components, such as crankshafts, piston rings, cylinders, valves, etc. In addition to these, they are also applied in the landing gear coating (bearings and axles inside the landing gear) to withstand the forces during landing and take-off.
- Most superalloy materials used to manufacture aircraft components and equipment possess good oxidation characteristics but are not corrosion and erosion resistant. Aviation components are subjected to harsh environments, exceptionally high heat, pressures, and abrasive chemicals. Thermal spray coatings significantly protect expensive engine components by extending the component life and improving performance.
- Thermal spray coatings, such as zirconium oxide, aluminum bronze, and cobalt-molybdenum, are used for coating purposes in rocket combustion chambers, compressor air seals, and high-pressure nozzles, respectively. In addition, chromium cobalt, aluminum oxide, and chromium carbide coatings are employed in turbine air seals, fuel nozzles, and turbine vanes. High-velocity oxy-fuel (HVOF) spray and plasma spray processes are the majorly used processes in this sector.
- In 2021, the United States contributed some USD 89.1 billion in aerospace exports, making it the leading country in aerospace exports. The country is home to some of the leading manufacturers in the aerospace sector, including Boeing and Lockheed Martin. As of 2021, six of the 12 leading aerospace and defense companies are based in the United States.
- Asia-Pacific and the Middle East & African regions are expected to witness rapid expansion in the aviation sector, owing to rising consumer incomes and investments in transportation infrastructure shortly.
- Asia-Pacific airlines registered substantial international growth four months in a row, reaching a year-on-year recovery rate of 453.3% in May, a significant increase from 103.5% in January 2022.
- Moreover, in 2021, the production value in the aerospace manufacturing industry was estimated to amount to approximately JPY 1.48 trillion (USD 13.96 billion), down from around JPY 1.61 trillion (USD 15.19 billion) in the previous fiscal year.
- All the factors mentioned above are expected to boost the consumption of thermal spray coatings in the aerospace industry during the forecast period.
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North America to Dominate the Market
- North America represented the largest regional market for global thermal spray coatings. The United States is expected to remain the region's primary market for thermal spray coatings, owing to the increasing demand for improved performance at competitive costs and meeting all the regulations and industry standards.
- The United States is one of the world's largest producers of the automotive industry. The country's automotive production recorded robust growth in 2021 after the pandemic. In 2021, automotive production stood at 9.17 million units 2021, a 4% growth from the previous year.
- Additionally, strong exports of aerospace components to countries such as France, China, and Germany, along with robust consumer spending in the United States, are driving the manufacturing activities in the aerospace industry.
- According to the Federal Aviation Administration (FAA), the total commercial aircraft fleet is expected to reach 8,270 by 2037 from 5,791 in 2021, owing to the growth in air cargo. Also, the US mainliner carrier fleet is expected to grow to 54 aircraft per year due to the existing fleet getting older.
- The Canadian aerospace industry contributed around USD 24 billion to the country's GDP in 2021. The Canadian aerospace industry exports over 75% of its products to over 190 countries across six continents.
- Such factors above, in turn, increase the demand for thermal spray coatings in the region during the forecast period.
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Thermal Spray Coatings Industry Overview
The global thermal spray coatings market is fragmented, with intense competition among the top players to capture a significant global market share. Most market leaders are vertically integrated, with a broad product portfolio of materials and equipment that is part of the overall thermal spray coatings market. Major players in the market include OC Oerlikon Management AG, Praxair S.T. Technologies Inc. (Linde PLC), Chromalloy Gas Turbine LLC, Kennametal Inc., and TOCALO Co. Ltd, among others (not in any particular order).
Thermal Spray Coatings Market Leaders
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OC Oerlikon Management AG
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Praxair S.T. Technologies Inc. (Linde PLC)
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Chromalloy Gas Turbine LLC
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Kennametal Inc.
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TOCALO Co. Ltd
- *Disclaimer: Major Players sorted in no particular order
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Thermal Spray Coatings Market News
- February 2023: Kennametal Inc. introduced a new, higher-performance turning grade with advanced coating technology. KCP25C with KENGold is the first choice for metal-cutting inserts with improved wear and higher metal removal rates for steel-turning applications.
- November 2022: Bodycote announced that it is expanding its thermal spray coatings capability in the Middle East. Bodycote entered into a partnership with Mathevon Group to develop the market in the region and, in particular, Saudi Arabia.
Thermal Spray Coatings Industry Segmentation
Thermal spray is an industrial coating process that heats or melts metallic or ceramic materials and deposits them onto a surface. The market is segmented into powder coating materials, process, end-user industry, and geography. By powder coating materials, the market is segmented into ceramic oxides, carbides, metals, polymers, and other powder-coating materials. By process, the market is segmented into combustion and electric energy. By end-user industry, the market is segmented into aerospace, industrial gas turbines, automotive, electronics, medical devices, energy and power, and other end-user industries. The report also covers the market size and forecasts for the thermal spray coatings market in 16 countries across major regions. The market sizing and forecasts for each segment are based on value (USD million).
| Powder Coating Materials | Ceramic Oxides | ||
| Carbides | |||
| Metals | |||
| Polymers and Other Powder Coating Materials | |||
| Process | Combustion | ||
| Electric Energy | |||
| End-user Industry | Aerospace | ||
| Industrial Gas Turbines | |||
| Automotive | |||
| Electronics | |||
| Medical Devices | |||
| Energy and Power | |||
| Oil and Gas | |||
| Other End-user Industries | |||
| Geography | Asia-Pacific | China | |
| India | |||
| Japan | |||
| South Korea | |||
| Australia & New Zealand | |||
| Rest of Asia-Pacific | |||
| North America | United States | ||
| Canada | |||
| Mexico | |||
| Europe | Germany | ||
| United Kingdom | |||
| Italy | |||
| France | |||
| Rest of Europe | |||
| South America | Brazil | ||
| Argentina | |||
| Rest of South America | |||
| Middle East and Africa | Saudi Arabia | ||
| South Africa | |||
| Rest of Middle East and Africa | |||
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Thermal Spray Coatings Market Research FAQs
What is the current Thermal Spray Coatings Market size?
The Thermal Spray Coatings Market is projected to register a CAGR of greater than 6% during the forecast period (2025-2030)
Who are the key players in Thermal Spray Coatings Market?
OC Oerlikon Management AG, Praxair S.T. Technologies Inc. (Linde PLC), Chromalloy Gas Turbine LLC, Kennametal Inc. and TOCALO Co. Ltd are the major companies operating in the Thermal Spray Coatings Market.
Which is the fastest growing region in Thermal Spray Coatings Market?
Asia Pacific is estimated to grow at the highest CAGR over the forecast period (2025-2030).
Which region has the biggest share in Thermal Spray Coatings Market?
In 2025, the North America accounts for the largest market share in Thermal Spray Coatings Market.
What years does this Thermal Spray Coatings Market cover?
The report covers the Thermal Spray Coatings Market historical market size for years: 2019, 2020, 2021, 2022, 2023 and 2024. The report also forecasts the Thermal Spray Coatings Market size for years: 2025, 2026, 2027, 2028, 2029 and 2030.
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Thermal Spray Coating Industry Report
Statistics for the 2025 Thermal Spray Coatings market share, size and revenue growth rate, created by Mordor Intelligence™ Industry Reports. Thermal Spray Coatings analysis includes a market forecast outlook for 2025 to 2030 and historical overview. Get a sample of this industry analysis as a free report PDF download.
