Thermal Spray Coatings Market research-Development Trends, Threats, Opportunities and Competitive Landscape in 2027

 

Market Highlights

Global Thermal Spray Coatings Market is projected to be valued at over USD 9.7 Billion by 2027 and exhibit a moderate CAGR of around 4.8% during the forecast period.

The growth of the global thermal spray coatings market is primarily driven by the healthy growth of the aerospace industry. In the aerospace industry, the use of high-quality thermal spray coatings results in increased fuel efficiency, reduced maintenance cost, and higher speed in aircraft and rotorcraft engines, as well as other related components. Typical thermal spray coatings applications include rotor-path linings, high-pressure turbine seals, compressor seals, bearings, oil seals, crankshafts, cylinders, and piston rings. The global commercial aircraft industry is expected to witness healthy growth in the coming years. Recovery in the global gross domestic product (GDP), stable commodity prices (including crude oil), growth in passenger travel, especially in Asia-Pacific, Latin America, and the Middle East, are expected to be the key factors driving the growth of the aerospace industry during the forecast period.

Additionally, thermal spray coatings are extensively used in the healthcare industry for various applications such as prosthetics, orthopedics, dental implants, and pacemakers. These coatings exhibit wear resistance, corrosion resistance, high temperature, and biocompatibility. The rising health concerns associated with the sedentary lifestyle and poor eating habits are likely to increase the number of patients suffering from various diseases, which is expected to boost the demand for implantable and surgeries, further fueling the global market. The demand for these surgeries is also promoted by the high disposable income of the consumers and their willingness to live a healthy life. All these factors are driving the demand for thermal spray coating in the healthcare industry and are expected to drive market growth during the review period.

However, thermal spray coatings have disadvantages as well. For instance, plasma spray coatings restrict access to surfaces, and small-diameter internal bores are challenging as it is a line-of-sight process and requires automated gun manipulators. Manual operation is deemed unsuitable. Moreover, thick coatings are difficult to achieve in thermal spray coatings.

 

Segment Analysis

Global Thermal Spray Coatings Market has been segmented based on Process, Material, and End User.

The global thermal spray coatings market, on the basis of process, is segmented into combustion flame and electrical. Combustion flame is the most commonly used thermal spray coating process accounting for a share of 69% of the global thermal spray coating market. The combustion flame process includes flame spraying, HVOC spraying, and detonation flame spraying. The flame spraying process is widely used for low-intensity applications owing to cost. HVOF (High-Velocity Oxygen Fuel) utilizes high-pressure oxygen and fuel gas; and provides a very dense coating, with low porosity and high bond strength to the metal substrate. HVOF is widely used for jet engine components, automotive components, gas turbines, and industrial machines.

Based on material, the global thermal spray coating market has been segmented into metals & alloys, ceramics, polymers, and others. The metal & alloys segment accounted for the largest share of the global thermal spray coatings market in 2019. Metal & alloy coating provides cost-effective surface solutions providing corrosion and oxidation resistance, wear and erosion resistance, and enhance conductivity. The segment includes tungsten, molybdenum, rhenium, niobium, superalloys, zinc, aluminum, stainless steels, NiCr alloys, cobalt-base, Stellites, cobalt/nickel-base, Tribaloys, and NiCrBSi "self-fluxing" alloys and zinc-aluminum alloy coatings. Some of the key applications of metals & alloy coatings include diesel engine cylinder coatings; piston rings or valve stems; turbine engine blades; vanes and combustors; corrosion-prone infrastructure; mining and agricultural equipment; and petrochemical pumps and valves.

 

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By end-user, the global thermal spray coating market has been segmented into aerospace, energy and power, automotive, healthcare, machinery, agriculture, electrical and electronics, and others. Thermal spray coatings are extensively used in the aerospace industry in gas turbine engines, air vessels, rocket exhaust cones, insulating tiles, space shuttles, windshield glass, and engine components. Increasing investment in the defense sector, improving commercial aviation networks, growth of the tourism industry, economic development, and an increase in the number of air passengers is expected to fuel aircraft production, thereby driving the demand for thermal spray coatings. Moreover, thermal spray coatings are extensively used in the aerospace industry in gas turbine engines, air vessels, rocket exhaust cones, insulating tiles, space shuttles, windshield glass, and engine components. Increasing investment in the defense sector, improving commercial aviation networks, growth of the tourism industry, economic development, and an increase in air passengers' number are expected to fuel aircraft production, thereby driving the demand for thermal spray coatings.

 

Key Players

MRFR has identified the following companies as the Key Players in the Global Thermal Spray Coatings Market — A&A Coatings (US), Oerlikon Group (Switzerland), BryCoat Inc. (US), Surface technology (UK), Bodycote (UK), Plasma-tec, Inc (Canada), General Magnaplate Corporation (US), ASB Industries (US), Exline, Inc (US), H. C. Starck (US), Metallisation Limited (UK), and Flame Spray Coating Company (US).

 

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