The global thermal spray coatings market was valued at approximately USD 10.46 billion in 2023, with projections indicating a growth rate of 4.8% CAGR from 2024 to 2030. The expansion of the thermal spray coatings market is closely tied to their application across various end-use industries, including automotive, aerospace, medical, industrial gas turbines, printing, steel, and pulp paper. A significant driver of this demand is the increasing use of gas turbines in critical applications such as helicopter engines, tanks, ships, and locomotives. Thermal spray coatings are particularly valued for their high-temperature and corrosion resistance, which safeguards components against damage in high-temperature and moisture-rich environments.

Gather more insights about the market drivers, restrains and growth of the Thermal Spray Coatings Market

Technology Segmentation Insights

In 2023, the plasma spray technology segment led the market, accounting for over 32.0% of revenue. This dominance is primarily due to the advantages this process offers, allowing the application of metallic and ceramic materials onto diverse surfaces with exceptional bond strength while minimizing substrate distortion for both large and small components. Plasma spray technology enhances the surface properties of substrates, providing electrical conductivity, clearance control, wear resistance, and heat and oxidation resistance. This method is commonly utilized for coating printing rolls, gas turbines, industrial diesel engine piston rings, and oil gas machinery. Moreover, it has found widespread adoption in the coating of orthopedic and dental implants, thanks to its ability to create dense and porous surface layers, which can be tailored to meet specific requirements regarding surface roughness and microstructure.

The increasing prevalence of orthopedic injuries and diseases, such as arthritis and osteoarthritis, along with a rapidly growing geriatric population—particularly in Europe and North America—are driving the demand for orthopedic implants. This trend is expected to further accelerate the growth of plasma thermal spray coatings technology in the coming years.

Cold spray technology, another significant segment, utilizes thermal energy to soften or melt the feedstock before impacting particles at high velocities onto a substrate. This technology is employed for applications in corrosion protection, electronics, and the automotive sector due to its compatibility with a wide range of materials, including various alloys, metals, composites, and refractory metals. The growth of cold spray technology is driven by its expanding applications across different end-use sectors.

A noteworthy example of cold spray technology in action occurred in April 2020 when members of the 28th Maintenance Squadron’s Additive Manufacturing and Rapid Repair Facility successfully conducted a cold spray repair on a B-1B Lancer Forward Equipment Bay (FEB) panel. This innovative repair method enhances aircraft availability while reducing operational costs by maintaining legacy aircraft components, which can positively influence the segment’s growth in the aerospace industry.

High-velocity oxy-fuel (HVOF) technology follows as another leading method in the global market. HVOF is employed to restore or enhance a component’s properties or geometry, facilitating the extension of equipment life. The advantages of HVOF over other technologies include lower porosity due to increased particle impact velocities, stronger bonds to the underlying substrate, reduced oxide content, smoother surfaces, enhanced wear resistance, and improved corrosion resistance. These benefits significantly contribute to the growth of the HVOF segment.

However, HVOF-sprayed coatings can be complex, as their properties and microstructures are influenced by numerous processing variables. Additionally, the powder sizes used in this technology are generally restricted to about 5 to 60 micrometers, which may limit its applications in certain contexts. Overall, the thermal spray coatings market is poised for continued growth, driven by technological advancements and increasing demand across various industries.

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