Thermal Spray Coating Market Outlook - 2027
The global thermal spray coating market size was valued at $8.0 billion in 2019, and is projected to reach $12.7 billion by 2027, growing at a CAGR of 5.9% from 2020 to 2027.
Thermal spray coating is a coating process which utilize powder coating material to coat a surface. The powder coating material is melted into droplets and sprayed onto a surface at a high velocity. The thermal spray coating is applied to metal substrates and the process is known by a different name that includes spray welding, plasma spray, High-Velocity Oxygen Fuel (HVOF), and flame spray. Thermal spray coating technology is used on a vast range of components of rotating and moving parts of machines such as automobile engines, aerospace turbine, and machine tools, which operate in adverse environments where, erosion, wear, corrosion, or heat leads to decrease in component life.
Increase in disposable income and expenditure power of consumers and improvement in standard of living across developing countries such as China and India increase the demand for automobiles. According to International Organization of Motor Vehicle Manufacturer (OICA), the automobile manufacturing production rate has been increased by 8% in 2018 as compared to year 2017. High-performance ceramic coatings are applied on automotive engine components to increase the fuel efficiency.
Its physical properties such as resistance to high temperature protect the components from oxidation. This factor is anticipated to increase the demand for thermal spray coatings. Once the thermal spray coating has been applied, it is often difficult to tell how well the coating has been absorbed, other than by a visual assessment. In addition, thermal spray coatings require very expensive apparatus, which can result in a high initial set up cost. This factors are likely to restrict the use of thermal spray coating, particularly in medical sector.
The growing automotive, aerospace, and heavy machinery industries and military & civil airliner has led to increase in usage of thermal spray coating technology. Thermal spray coating is used to coat piston and synchronizer rings in automotive applications. Similarly, thermal spray coating is also used in aerospace application to coat engine turbine blades and protect it from extreme temperatures, as well as ensure increased reliability for ex- tended periods of time. These coatings are replacing hard chromium plating as the preferred coating method to offer improved performance. This factor is anticipated to drive the growth of the market.
The global thermal spray coating market is segmented based on material, process, end-use industry and region. Based on material, the global market is segmented into ceramics, metal & alloys and other materials. Covering materials accessible for thermal spray incorporate metals, alloys, ceramics, plastics and composites. They are fed in powder or wire structure, warmed to a liquid or semi molten state and coated towards substrates as micrometer-size particles. Based on material, the global market is segmented into ceramics, metal & alloys and other material such as plastic and composite. The metal & alloys segment is estimated to grow with the highest CAGR during the forecast period.
By Material
Metal & Alloys is projected to grow with a CAGR of 6.3% during the forecast period.
Based on process, the global thermal spray coating market size is bifurcated into flame spraying, arc spraying, plasma spraying, HVOF and others. The flame spraying segment was the highest contributor to the market. Flame spraying process is cost effective and hence are increasingly used for corrosion protection and to enhance the performance of surface. Aluminum, zinc, stainless steel, bronze, low carbon steel, nickel-based materials, molybdenum are materials used in this process. The plasma spraying segment is estimated to grow with the highest CAGR during the forecast period.
By Process
Plasma Spraying is projected as the most lucrative segment.
On the basis of end-use industry, the market is divided into automotive, aerospace, industrial and others. The aerospace segment was the highest contributor to the market. North America reported a greater demand for thermal spray coatings due to the established aerospace industry and increased investment in a similar sector to produce technologically advanced space vehicles. This factor is anticipated to allow manufacturers to produce weight-saving aircraft engines by creating enormous growth opportunities for ceramic material. As aircraft manufacturers are increasingly adopting ceramic material in engines of aircraft, the competition among them is growing, ultimately resulting in increased demand for thermal spray coating. The automotive segment is estimated to grow with the highest CAGR during the forecast period.
By End-user Industry
Automotive is projected as the most lucrative segment.
Based on region, the market is analyzed across North America, Asia-Pacific, Europe and LAMEA. Asia-Pacific was the dominant region in 2019 and is contributing significantly towards thermal spray coating market growth. China is expected to be the major player in the thermal spray coatings market due to demand from various end use industries such as automotive, oil & gas exploration, and healthcare. The market in Asia-Pacific is driven by the rise in demand in the automotive industry, growth in disposable income of consumers in the region, and increase in usage in the healthcare industry.
By Region
Asia-Pacific would exhibit a CAGR of 6.3% during 2020-2027.
The major key players operating in the 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 and Morgan Advanced Materials plc. Other players contributing towards thermal spray coating market share include Fosbel, Keronite Group, Oerlikon Metco, and Swain Tech Coatings. These major key players are adopting different strategies such as acquisition, business expansion, and collaboration to stay competitive in the global market.
Key benefits for stakeholders
- The report provides extensive qualitative and quantitative analyses of the current thermal spray coating market trends and future estimations of the market from 2019 to 2027 to determine the prevailing opportunities.
- Comprehensive analysis of factors that drive and restrict the thermal spray coating market growth is provided.
- Estimations and forecast are based on factors impacting the market growth, in terms of both value and volume.
- Profiles of leading players operating in the global thermal spray coating market analysis are provided, and this helps in understanding the competitive scenario globally.
- The report provides extensive qualitative insights on the significant segments and regions exhibiting favorable market growth.
- The global thermal spray coating market forecast is done from 2020 to 2027.
Thermal Spray Coating Market Report Highlights
| Aspects | Details |
 By Material |
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 By Process |
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 By End Use Industry |
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 By Region |
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 Key Market Players | COORSTEK, INC., 3M, INC., SAINT-GOBAIN, MORGAN ADVANCED MATERIALS PLC, DUPONT DE NEMOURS, INC, A&A THERMAL SPRAY COATINGS, INC., APS MATERIAL, INC., LINDE PLC, INTEGRATED GLOBAL SERVICES, INC., KCC CORPORATION |
Analyst Review
The thermal spray coating market is expected to witness substantial growth during the forecast period, owing to various factors such as development of the automotive and aerospace & defense industries and surge in usage of thermal spray coating in medical devices.
These coatings are witnessing outstanding acceptance due to their corrosion and erosion resistance properties. Thermal spray coating leads to superior bond strength, low porosity, resistance to erosion-corrosion, and hence are increasingly used in the automotive sector.
Thermal spraying technique has undergone several technological advancements over the years. Introduction of plasma spraying is one such advancement. This technique used powder feedstock and high temperature plasma to melt and apply metal coatings to a substrate. Such advancement is further expected to contribute towards the growing usage of thermal spray coating.
the thermal spray coating market is expected to witness substantial growth during the forecast period, owing to various factors such as development of the automotive and aerospace & defense industries and surge in usage of thermal spray coating in medical devices.
The global thermal spray coating market was valued at $8.0 billion in 2019, and is projected to reach $12.7 billion by 2027, growing at a CAGR of 5.9% from 2020 to 2027.
The major key players operating in the 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 and Morgan Advanced Materials plc.
The aerospace segment was the highest contributor to the market. North America reported a greater demand for thermal spray coatings due to the established aerospace industry and increased investment in a similar sector to produce technologically advanced space vehicles.
The flame spraying segment was the highest contributor to the market. Flame spraying process is cost effective and hence are increasingly used for corrosion protection and to enhance the performance of surface.
Once the thermal spray coating has been applied, it is often difficult to tell how well the coating has been absorbed, other than by a visual assessment. In addition, thermal spray coatings require very expensive apparatus, which can result in a high initial set up cost. These factors are anticipated to restrict the use of thermal spray coating, particularly in the medical sector.
Asia-Pacific was the dominant region in 2019 and is contributing significantly towards thermal spray coating market growth. China is expected to be the major player in the thermal spray coatings market due to demand from various end use industries such as automotive, oil & gas exploration, and healthcare.
Extended lockdown across the globe negatively affected the global supply chain of the thermal spray coatings. Regulations on cross-border imports and exports delayed the lead time for replenishment of raw materials; thereby, negatively affecting the upstream process.
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