Thermal Spray Coatings Market, By Material, By Process, By Application, By Geography

Description

Global Thermal Spray Coatings Market is estimated to be valued at USD 11.88 Bn in 2025 and is expected to reach USD 18.96 Bn by 2032, growing at a compound annual growth rate (CAGR) of 6.9% from 2025 to 2032.

Report Coverage		Report Details
Base Year:	2024	Market Size in 2025:	USD 11.88 Bn
Historical Data for:	2020 To 2024	Forecast Period:	2025 To 2032
Forecast Period 2025 to 2032 CAGR:	6.90%	2032 Value Projection:	USD 18.96 Bn

Figure. Thermal Spray Coatings Market Share (%), By Region 2025

Thermal spray coatings refer to the process of spraying molten or heated materials, such as metal, alloys, or ceramics, onto the surface of a substrate material to obtain a dense ceramic or metallurgic bond coating. Thermal spray technology is gaining widespread acceptance in various end-use industries owing to its unique advantages such as versatility, ability to spray a wide variety of materials, and coat quality matching expensive bond coats. The process helps improve surface properties of the substrate materials including wear and corrosion resistance, oxidation resistance at elevated temperatures, and electrical conductivity. Rising demand from the aerospace, industrial gas turbines, automotive, and healthcare industries is expected to drive the growth of the global thermal spray coatings market over the forecast period.

Market Dynamics:

The global thermal spray coatings market is driven by factors such as the growing demand for wear and corrosion resistant coatings from end-use industries, increasing utilization of thermal spray technology in repair and maintenance activities, and stringent environmental regulations regarding volatile organic compound emissions from conventional liquid coatings. However, high capital investments for the procurement of thermal spray equipment and availability of competitive technologies such as physical and chemical vapor depositions are expected to restrain the market growth. On the other hand, the development of nanostructured and bio-compatible thermal spray coatings present new opportunities for market participants. In addition, thermal spray technology offers an economical alternative to expensive bond coats and has high transfer efficiency of materials, thereby reducing wastage.

Key Features of the Study:

This report an provides in-depth analysis of the global thermal spray coatings market, and provides market size (US$ Bn) and compound annual growth rate (CAGR%) for the forecast period (2025-2032), considering 2024 as the base year
It elucidates potential revenue growth opportunities across different segments and explains attractive investment proposition matrices for this market
This study also provides key insights about market drivers, restraints, opportunities, new product launches or approvals, market trends, regional outlook, and competitive strategies adopted by key players
It profiles key players in the global thermal spray coatings market based on the following parameters - company highlights, products portfolio, key highlights, financial performance, and strategies
Key companies covered as a part of this study include Praxair Surface Technologies , H.C. Starck, Bodycote PLC, Oerlikon Metco, Surface Technology International Ltd, ASB Industries Inc., A&A Coatings, Flame Spray Technologies, Metallisation Ltd , TWI Ltd , Metallizing Equipment Co. Pvt. Ltd. , Plasma-Tec, Inc. , Integrated Global Services, Progressive Surface , FST Coatings Inc., Thermion Inc. , Oerlikon Balzers , Tafa Incorporated , Metallizing Equipment Co. Pvt. Ltd., and TST Coatings, Inc
Insights from this report would allow marketers and the management authorities of the companies to make informed decisions regarding their future product launches, type up-gradation, market expansion, and marketing tactics
The global thermal spray coatings market report caters to various stakeholders in this industry including investors, suppliers, product manufacturers, distributors, new entrants, and financial analysts
Stakeholders would have ease in decision-making through various strategy matrices used in analyzing the global thermal spray coatings market

Detailed Segmentation-

By Material:
- Metals
- Alloys
- Carbides
- Ceramics
- Intermetallic
- Others
By Process:
- Conventional Flame Spray
- Plasma Spray
- Retail Stores
- HVOF (High Velocity Oxy-fuel)
- Cold Spray
- Others
By Application:
- Aerospace
- Industrial Gas Turbines
- Automotive
- Medical
- Others
By Region:
- North America
- Europe
- Asia Pacific
- Latin America
- Middle East & Africa
Company Profiles:
- Praxair Surface Technologies
- H.C. Starck
- Bodycote PLC
- Oerlikon Metco
- Surface Technology International Ltd
- ASB Industries Inc.
- A&A Coatings
- Flame Spray Technologies
- Metallisation Ltd
- TWI Ltd
- Metallizing Equipment Co. Pvt. Ltd.
- Plasma-Tec, Inc.
- Integrated Global Services
- Progressive Surface
- FST Coatings Inc.
- Thermion Inc.
- Oerlikon Balzers
- Tafa Incorporated
- Metallizing Equipment Co. Pvt. Ltd.
- TST Coatings, Inc

Product Code: CMI3275

1. Research Objectives and Assumptions

Research Objectives
Assumptions
Abbreviations

2. Market Purview

Report Description
- Market Definition and Scope
Executive Summary
- Market Snippet, By Material
- Market Snippet, By Process
- Market Snippet, By Application
- Market Snippet, By Region
Coherent Opportunity Map (COM)

3. Market Dynamics, Regulations, and Trends Analysis

Market Dynamics
- Drivers
- Restraints
- PEST Analysis
- PORTER's Five Forces Analysis
- Market Opportunities
- Regulatory Scenario
- Industry Trend
- Mergers and Acquisitions

4. Global Thermal Spray Coatings Market - Impact of Coronavirus (COVID-19) Pandemic

Overview
Factors Affecting the Global Thermal Spray Coatings Market
Impact Analysis

5. Global Thermal Spray Coatings Market, By Material, 2020-2032, (US$ Bn & KT)

Introduction
- Market Share Analysis, 2025, 2028 and 2032 (%)
- Y-o-Y Growth Analysis, 2020 - 2032
- Segment Trends
Metals
- Market Share Analysis, 2025, 2028 and 2032 (%)
- Y-o-Y Growth Analysis, 2020 - 2032
- Segment Trends
Alloys
- Market Share Analysis, 2025, 2028 and 2032 (%)
- Y-o-Y Growth Analysis, 2020 - 2032
- Segment Trends
Carbides
- Market Share Analysis, 2025, 2028 and 2032 (%)
- Y-o-Y Growth Analysis, 2020 - 2032
- Segment Trends
Ceramics
- Market Share Analysis, 2025, 2028 and 2032 (%)
- Y-o-Y Growth Analysis, 2020 - 2032
- Segment Trends
Intermetallic
- Market Share Analysis, 2025, 2028 and 2032 (%)
- Y-o-Y Growth Analysis, 2020 - 2032
- Segment Trends
Others
- Market Share Analysis, 2025, 2028 and 2032 (%)
- Y-o-Y Growth Analysis, 2020 - 2032
- Segment Trends

6. Global Thermal Spray Coatings Market, By Process, 2020-2032, (US$ Bn & KT)

Introduction
- Market Share Analysis, 2025, 2028 and 2032 (%)
- Y-o-Y Growth Analysis, 2020 - 2032
- Segment Trends
Conventional Flame Spray
- Market Share Analysis, 2025, 2028 and 2032 (%)
- Y-o-Y Growth Analysis, 2020 - 2032
- Segment Trends
Plasma Spray
- Market Share Analysis, 2025, 2028 and 2032 (%)
- Y-o-Y Growth Analysis, 2020 - 2032
- Segment Trends
Retail Stores
- Market Share Analysis, 2025, 2028 and 2032 (%)
- Y-o-Y Growth Analysis, 2020 - 2032
- Segment Trends
HVOF (High Velocity Oxy-fuel)
- Market Share Analysis, 2025, 2028 and 2032 (%)
- Y-o-Y Growth Analysis, 2020 - 2032
- Segment Trends
Cold Spray
- Market Share Analysis, 2025, 2028 and 2032 (%)
- Y-o-Y Growth Analysis, 2020 - 2032
- Segment Trends
Others
- Market Share Analysis, 2025, 2028 and 2032 (%)
- Y-o-Y Growth Analysis, 2020 - 2032
- Segment Trends

7. Global Thermal Spray Coatings Market, By Application, 2020-2032, (US$ Bn & KT)

Introduction
- Market Share Analysis, 2025, 2028 and 2032 (%)
- Y-o-Y Growth Analysis, 2020 - 2032
- Segment Trends
Aerospace
- Market Share Analysis, 2025, 2028 and 2032 (%)
- Y-o-Y Growth Analysis, 2020 - 2032
- Segment Trends
Industrial Gas Turbines
- Market Share Analysis, 2025, 2028 and 2032 (%)
- Y-o-Y Growth Analysis, 2020 - 2032
- Segment Trends
Automotive
- Market Share Analysis, 2025, 2028 and 2032 (%)
- Y-o-Y Growth Analysis, 2020 - 2032
- Segment Trends
Medical
- Market Share Analysis, 2025, 2028 and 2032 (%)
- Y-o-Y Growth Analysis, 2020 - 2032
- Segment Trends
Others
- Market Share Analysis, 2025, 2028 and 2032 (%)
- Y-o-Y Growth Analysis, 2020 - 2032
- Segment Trends

8. Global Thermal Spray Coatings Market, By Region, 2020-2032, (US$ Bn & KT)

Introduction
- Market Share Analysis, By Region, 2025, 2028 and 2032 (%)
- Y-o-Y Growth Analysis, For Region, 2021-2032
North America
- Introduction
- Market Size and Forecast, By Application, 2020 - 2032, (US$ Bn & KT)
- Market Size and Forecast, By Process, 2020 - 2032, (US$ Bn & KT)
- Market Size and Forecast, By Application, 2020 - 2032, (US$ Bn & KT)
- Market Size and Forecast, By Country, 2020 - 2032, (US$ Bn & KT)
  - U.S.
  - Canada
Latin America
- Introduction
- Market Size and Forecast, By Application, 2020 - 2032, (US$ Bn & KT))
- Market Size and Forecast, By Process, 2020 - 2032, (US$ Bn & KT)
- Market Size and Forecast, By Application, 2020 - 2032, (US$ Bn & KT)
- Market Size and Forecast, By Country, 2020 - 2032, (US$ Bn & KT)
  - Brazil
  - Argentina
  - Mexico
  - Rest of Latin America
Europe
- Introduction
- Market Size and Forecast, By Application, 2020 - 2032, (US$ Bn & KT)
- Market Size and Forecast, By Process, 2020 - 2032, (US$ Bn & KT)
- Market Size and Forecast, By Application, 2020 - 2032, (US$ Bn & KT)
- Market Size and Forecast, By Country, 2020 - 2032, (US$ Bn & KT)
  - U.K.
  - Germany
  - Italy
  - France
  - Spain
  - Russia
  - Rest of Europe
Asia Pacific
- Introduction
- Market Size and Forecast, By Application, 2020 - 2032, (US$ Bn & KT)
- Market Size and Forecast, By Process, 2020 - 2032, (US$ Bn & KT)
- Market Size and Forecast, By Application, 2020 - 2032, (US$ Bn & KT)
- Market Size and Forecast, By Country, 2020 - 2032, (US$ Bn & KT)
  - China
  - India
  - Japan
  - ASEAN
  - Australia
  - South Korea
  - Rest of Asia Pacific
Middle East & Africa
- Introduction
- Market Size and Forecast, By Application, 2020 - 2032, (US$ Bn & KT)
- Market Size and Forecast, By Process, 2020 - 2032 (US$ Bn & KT)
- Market Size and Forecast, By Application, 2020 - 2032, (US$ Bn & KT)
- Market Size and Forecast, By Country, 2020 - 2032, (US$ Bn & KT)
  - GCC Countries
  - Israel
  - Rest of Middle East & Africa

9. Competitive Landscape

Market Share Analysis
Company Profiles
- Praxair Surface Technologies
  - Company Overview
  - Product Portfolio
  - Recent Developments/Updates
- H.C. Starck
  - Company Overview
  - Product Portfolio
  - Recent Developments/Updates
- Bodycote PLC
  - Company Overview
  - Product Portfolio
  - Recent Developments/Updates
- Oerlikon Metco
  - Company Overview
  - Product Portfolio
  - Recent Developments/Updates
- Surface Technology International Ltd
  - Company Overview
  - Product Portfolio
  - Recent Developments/Updates
- ASB Industries Inc.
  - Company Overview
  - Product Portfolio
  - Recent Developments/Updates
- A&A Coatings
  - Company Overview
  - Product Portfolio
  - Recent Developments/Updates
- Flame Spray Technologies
  - Company Overview
  - Product Portfolio
  - Recent Developments/Updates
- Metallisation Ltd
  - Company Overview
  - Product Portfolio
  - Recent Developments/Updates
- TWI Ltd
  - Company Overview
  - Product Portfolio
  - Recent Developments/Updates
- Metallizing Equipment Co. Pvt. Ltd.
  - Company Overview
  - Product Portfolio
  - Recent Developments/Updates
- Plasma-Tec, Inc.
- Integrated Global Services
- Progressive Surface
- FST Coatings Inc.
- Thermion Inc.
- Oerlikon Balzers
- Tafa Incorporated
- Metallizing Equipment Co. Pvt. Ltd.
- TST Coatings, Inc

10. Analyst Recommendation

Wheel of Fortune
Analyst View
Coherent Opportunity Map

11. Section

References
Research Methodology
About Us and Sales Contact