Report Description

Forecast Period


Market Size (2022)

USD 1.52 billion

CAGR (2023-2028)


Fastest Growing Segment

Ceramic Oxide

Largest Market



Market Overview

United States Thermal Spray Coatings Market has valued at USD 1.52 billion in 2022 and is anticipated to project robust growth in the forecast period with a CAGR of 4.75% through 2028. United States market for thermal spray adhesives has been witnessing significant growth in recent years, driven by the burgeoning demand across various industries for advanced adhesion solutions. Thermal spray adhesives, also known as thermal spray coatings, play a pivotal role in enhancing the performance, durability, and reliability of surfaces subjected to extreme conditions. Thermal spray adhesives involve a specialized coating process where a material is heated and propelled onto a surface using a thermal spray gun. The molten particles adhere to the substrate, forming a resilient and protective coating. This method is employed across diverse industries for purposes ranging from corrosion resistance to enhancing thermal insulation. The future of the thermal spray adhesives market looks promising, with continuous technological advancements and a growing focus on sustainability. As industries continue to seek reliable and durable solutions for surface protection, the demand for thermal spray adhesives is expected to rise.

Key Market Drivers

Growing Industrialization

Industrialization, characterized by increased manufacturing, infrastructure development, and economic growth, has become a pivotal force in shaping the demand dynamics of thermal spray coatings. As nations strive for economic development, there is a simultaneous need to ensure the reliability and longevity of industrial components subjected to rigorous operating conditions.

Industries such as manufacturing, automotive, and energy are witnessing a surge in demand for thermal spray coatings to augment the performance and durability of critical components. The increased production volumes and operational demands necessitate innovative solutions for surface protection against wear, corrosion, and extreme temperatures.

Furthermore, the growing industrialization trend has led to an increased focus on enhancing operational efficiency. Thermal spray coatings play a crucial role in achieving this objective by providing cost-effective and efficient solutions for extending the lifespan of machinery and components. Industries are recognizing the long-term benefits of investing in advanced coating technologies to minimize downtime, reduce maintenance costs, and enhance overall equipment performance.

In the wake of this industrial revolution, market players in the thermal spray coatings industry are strategically positioning themselves to meet the escalating demand. The adoption of cutting-edge technologies and continuous research and development initiatives are further amplifying the industry's response to the evolving needs of industrialization.

Technological Advancements

One of the primary catalysts for market growth is the continuous refinement and development of thermal spray technologies. Advancements in materials, application methods, and equipment are expanding the capabilities of thermal spray coatings, allowing them to cater to a broader spectrum of industrial needs. From aerospace to energy, automotive, and beyond, the versatility of thermal spray coatings is amplified by breakthroughs in plasma spraying, high-velocity oxy-fuel spraying (HVOF), and cold spraying techniques.

The aerospace and automotive industries, in particular, are witnessing a transformative impact. Technological innovations in thermal barrier coatings, corrosion-resistant coatings, and wear-resistant coatings are enabling aircraft components and automotive parts to withstand extreme conditions, contributing to increased operational efficiency and extended lifespan.

Moreover, the development of environmentally friendly coating materials and processes is aligning the thermal spray coatings market with sustainability goals. As industries worldwide become increasingly conscious of their environmental footprint, the demand for eco-friendly and energy-efficient solutions is driving research and development initiatives in the thermal spray coatings sector.

Need for Surface Protection

Industries spanning manufacturing, energy, automotive, and aerospace are witnessing a surge in the adoption of thermal spray coatings, driven by the critical requirement to safeguard vital components from degradation and deterioration. The escalating need for surface protection arises from the inherent challenges posed by aggressive operating conditions, which, if left unchecked, can compromise the integrity and functionality of industrial equipment. Thermal spray coatings have emerged as a linchpin in the quest for comprehensive surface protection. These coatings, applied through advanced techniques such as plasma spraying and high-velocity oxy-fuel spraying, create a resilient shield that fortifies surfaces against the ravages of time and environmental stressors. In the oil and gas sector, for instance, pipelines coated with thermal spray materials are better equipped to resist corrosion, ensuring the uninterrupted flow of energy resources. Furthermore, the imperative for surface protection is intricately tied to the pursuit of operational efficiency. Industries recognize that investing in advanced coating solutions is not merely a preventive measure but a strategic imperative. Thermal spray coatings minimize downtime, curtail maintenance costs, and extend the service life of critical machinery, thus enhancing overall operational efficiency.


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Key Market Challenges

High Initial Investments

At the heart of this challenge lies the sophisticated and specialized nature of thermal spray technology. The process demands state-of-the-art equipment, including thermal spray guns, robotic systems, and spray booths, which collectively contribute to a substantial upfront cost. For smaller businesses with limited financial resources, this financial commitment can be prohibitive, preventing them from harnessing the benefits of thermal spray coatings to fortify their industrial assets.

The initial investment encompasses not only the acquisition of specialized machinery but also the costs associated with training personnel to operate the equipment effectively. The intricate nature of thermal spray processes necessitates skilled professionals, and the training programs can further strain the financial resources of businesses looking to venture into thermal spray applications.

Moreover, the challenge is accentuated by the need for a dedicated workspace equipped with adequate ventilation systems and safety measures. Creating such an environment compliant with industry standards requires additional investment, adding to the overall cost of entry into the thermal spray coatings market.

While large enterprises may absorb these initial costs more comfortably, for smaller players or those operating on tight budgets, the financial barrier becomes a substantial impediment. This not only limits the market accessibility but also potentially stifles innovation and diversity within the thermal spray coatings industry.

Complexity of Technology

At the core of this challenge is the requirement for specialized knowledge and skills. The intricate procedures of thermal spray coatings, including techniques such as plasma spraying and high-velocity oxy-fuel spraying, demand a high level of expertise for optimal implementation. This complexity is not only a barrier for new entrants but also presents ongoing challenges for companies seeking to scale their thermal spray operations.

The diverse range of thermal spray materials, each tailored for specific applications, adds another layer of intricacy. Choosing the right material requires a nuanced understanding of the desired coating properties, environmental conditions, and the characteristics of the substrate. This complexity makes the technology less accessible for industries without in-house experts or dedicated research and development teams.

Furthermore, the constant evolution of thermal spray technologies introduces a dynamic element to the market. Staying abreast of the latest advancements, adapting to new materials, and integrating cutting-edge techniques into existing processes become imperative. For businesses, this continual learning curve demands significant investments in research and development, training programs, and equipment upgrades.

Key Market Trends

Focus on Environmental Sustainability

As industries across the globe grapple with the imperative of reducing their environmental footprint, thermal spray coatings are emerging as a key ally in this endeavour. The traditional methods of coating surfaces often involve the use of environmentally harmful materials and processes. In contrast, thermal spray coatings offer an eco-friendlier alternative, contributing to a cleaner and greener industrial landscape.

One of the primary ways in which thermal spray coatings align with sustainability goals is through the use of environmentally friendly coating materials. Companies in the market are increasingly investing in the development of coatings that minimize the environmental impact without compromising on performance. This shift not only addresses regulatory concerns but also resonates with the growing awareness and demand for sustainable practices among consumers and businesses alike.

Furthermore, the thermal spray coatings market is witnessing innovations in energy-efficient coating processes. Manufacturers are exploring techniques that reduce energy consumption during the coating application, thus contributing to a more sustainable and resource-efficient industry. This not only aligns with corporate social responsibility initiatives but also positions thermal spray coatings as a responsible choice for environmentally conscious businesses.

Rising Demand for High Performance Coatings

At the heart of this market evolution is the relentless pursuit of efficiency, durability, and resilience in industrial operations. High-performance coatings, facilitated by thermal spray technologies, have become indispensable for sectors such as aerospace, automotive, energy, and manufacturing. These coatings offer unparalleled resistance to wear, corrosion, and high temperatures, making them the go-to solution for industries grappling with the challenges of demanding operating environments.

In the aerospace industry, where components are exposed to extreme conditions during flight, the demand for thermal spray coatings has soared. Turbine blades, engine components, and other critical parts benefit from the protective shield provided by high-performance thermal spray coatings, enhancing overall performance and extending the lifespan of aircraft components.

Similarly, the automotive sector is leveraging the advantages of high-performance thermal spray coatings to achieve enhanced fuel efficiency, reduced maintenance costs, and prolonged component life. From engine components to exhaust systems, these coatings play a pivotal role in optimizing automotive performance and longevity.

The energy sector, encompassing power generation and oil and gas industries, relies on thermal spray coatings to protect vital components from corrosion, erosion, and thermal stress. As the United States demand for energy continues to rise, the need for high-performance coatings that can withstand the rigors of energy production becomes increasingly critical.

Growth in Renewable Energy Applications

Renewable energy, encompassing wind, solar, and hydropower, has emerged as a pivotal sector with a burgeoning demand for advanced technologies that can withstand the rigors of harsh environmental conditions. Thermal spray coatings have stepped into this arena as a linchpin, providing a robust solution for protecting critical components in renewable energy infrastructure.

Wind energy, in particular, stands out as a significant driver for the thermal spray coatings market. The blades of wind turbines, subjected to relentless exposure to wind, rain, and environmental pollutants, demand high-performance coatings for longevity and efficiency. Thermal spray coatings, with their ability to resist corrosion, erosion, and thermal stress, have become instrumental in ensuring the durability and reliability of wind turbine components.

Solar energy applications also benefit from thermal spray coatings, where protective coatings are applied to solar panels to enhance resistance against environmental degradation. The ability of these coatings to withstand extreme temperatures and provide a shield against wear contributes to the overall efficiency and lifespan of solar panels.

As the world pivots towards renewable energy to address climate change concerns, the demand for thermal spray coatings is set to experience an unprecedented surge. Governments and industries United Statesly are investing heavily in renewable energy projects, propelling the thermal spray coatings market into a position of strategic importance.

Segmental Insights

Material Insights

Ceramic oxide coatings are revered for their exceptional wear resistance, thermal insulation, and electrical insulation properties. Materials like alumina (Al2O3) and zirconia (ZrO2) dominate this category, offering coatings that find applications in aerospace, automotive, and electronics industries. These coatings provide a protective barrier against extreme temperatures, corrosion, and abrasive wear.

Carbide-based thermal spray coatings, such as tungsten carbide (WC) and chromium carbide (Cr3C2), are renowned for their hardness and resistance to abrasion. These coatings are extensively used in applications where components are subjected to severe wear conditions, such as in the oil and gas industry. Carbide coatings contribute to the longevity of components exposed to challenging operational environments.

Metals, including alloys like stainless steel, nickel-chrome, and aluminum, play a crucial role in thermal spray coatings. These coatings are valued for their versatility, conductivity, and corrosion resistance. Applications range from protecting components in the aerospace industry to providing anti-corrosive coatings in marine environments.

Polymer-based thermal spray coatings offer unique advantages, including flexibility, impact resistance, and electrical insulation. Polymers such as polyimide and polytetrafluoroethylene (PTFE) find applications in the aerospace and electronics industries. These coatings provide a protective layer while offering flexibility and thermal stability.

End User Industry Insights

The automotive industry stands at the forefront of leveraging thermal spray coatings to enhance performance and longevity. Components such as engine parts, pistons, and exhaust systems are subjected to extreme conditions. Thermal spray coatings, often composed of metals or ceramics, provide a protective layer against wear, corrosion, and thermal stress, contributing to increased fuel efficiency and reduced maintenance costs.

In the aerospace sector, where precision and reliability are paramount, thermal spray coatings play a pivotal role. Turbine blades, combustion chambers, and other critical components are subjected to extreme temperatures and harsh environments. Thermal barrier coatings, often composed of ceramic materials, provide thermal insulation and protect against corrosion, ensuring the durability and efficiency of aerospace components.

The energy and power industry relies on thermal spray coatings for the protection of critical components in power plants and renewable energy infrastructure. Components exposed to high temperatures, such as boiler tubes and gas turbine blades, benefit from coatings that enhance resistance to corrosion and erosion. In the renewable energy sector, thermal spray coatings contribute to the longevity of wind turbine components, ensuring sustainable energy production.

In the electronics industry, where precision meets miniaturization, thermal spray coatings find applications in coating electronic components. Polymers and ceramics are often used to provide insulation, protection against environmental factors, and enhance the performance of electronic devices. Thermal spray coatings contribute to the reliability of electronic components in various applications.

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Regional Insights

  • One of the primary factors fueling the growth of the thermal spray coatings market in Midwest is the robust industrialization and infrastructure development witnessed across the region. As nations invest heavily in expanding their industrial capacities, the demand for advanced surface protection technologies, such as thermal spray coatings, has witnessed an unprecedented surge. Industries ranging from automotive and aerospace to energy and manufacturing are leveraging thermal spray coatings to enhance the durability and performance of critical components.
  • Moreover, the automotive sector in Midwest, which is experiencing exponential growth, is a major consumer of thermal spray coatings. As the automotive industry in countries like China and India continues to expand, the need for coatings that provide corrosion resistance, thermal insulation, and wear protection is escalating. Thermal spray coatings, with their ability to meet these requirements, have become integral to the manufacturing processes in the region.
  • In the aerospace industry, particularly in countries like Japan, where technological advancements are synonymous with innovation, thermal spray coatings are witnessing increased adoption. These coatings play a vital role in protecting aerospace components subjected to extreme conditions, contributing to the efficiency and longevity of aircraft and spacecraft.
  • The Midwest region's focus on renewable energy initiatives has also propelled the demand for thermal spray coatings. As countries invest in wind energy projects, the coatings are essential for protecting wind turbine components from environmental stressors, contributing to sustainable energy production.
  • Furthermore, the Midwest region is a hub for technological innovation and research. Ongoing developments in material science, application techniques, and coating technologies are enriching the thermal spray coatings market. Collaborations between research institutions, government bodies, and industry players are fostering an environment conducive to advancements in the field.

Recent Developments

  • In July 2019, Oerlikon Metco revealed its commitment to acquiring AMT AG, a Swiss firm specializing in the design and construction of comprehensive thermal spray coating systems. This strategic move aligns with Oerlikon's goal of focusing and expanding its surface solution technologies, aiming to enhance accessibility for commercial applications and services.

Key Market Players

  • APS Materials Inc
  • ASB Industries Inc.
  • Bodycote PLC
  • Chromalloy Gas Turbine LLC
  • Eurocoating SpA
  • FM Industries Inc.
  • FW Gartner Thermal Spraying (Curtis-Wright)
  • Kennametal Inc.
  • Oerlikon Metco
  • Praxair S.T. Technology, Inc.

 By Material

By End User Industry

By Region

  • Ceramic oxide
  • Carbides
  • Metals
  • Polymer
  • Others
  • Automotive
  • Aerospace
  • Energy and Power
  • Electronics
  • Oil and Gas
  • Others
  • West
  • Midwest
  • Northeast
  • South


Report Scope:

In this report, the United States Thermal Spray Coatings Market has been segmented into the following categories, in addition to the industry trends which have also been detailed below:

  • Thermal Spray Coatings Market, By Material:

o   Ceramic Oxide

o   Carbides

o   Metals

o   Polymer

o   Others

  • Thermal Spray Coatings Market, By End User Industry:

o   Automotive

o   Aerospace

o   Energy and Power

o   Electronics

o   Oil and Gas

o   Others

  • Thermal Spray Coatings Market, By Region:

o   West

o   Midwest

o   Northeast

o   South

Competitive Landscape

Company Profiles: Detailed analysis of the major companies present in the United States Thermal Spray Coatings Market.

Available Customizations:

United States Thermal Spray Coatings market report with the given market data, Tech Sci Research offers customizations according to a company's specific needs. The following customization options are available for the report:

Company Information

  • Detailed analysis and profiling of additional market players (up to five).

United States Thermal Spray Coatings Market is an upcoming report to be released soon. If you wish an early delivery of this report or want to confirm the date of release, please contact us at [email protected]

Table of content

1.    Product Overview

1.1.  Market Definition

1.2.  Scope of the Market

1.2.1.     Markets Covered

1.2.2.     Years Considered for Study

1.2.3.     Key Market Segmentations

2.    Research Methodology

2.1.  Objective of the Study

2.2.  Baseline Methodology

2.3.  Key Industry Partners

2.4.  Major Association and Secondary Applications

2.5.  Forecasting Methodology

2.6.  Data Triangulation & Validation

2.7.  Assumptions and Limitations

3.    Executive Summary

3.1.  Overview of the Market

3.2.  Overview of Key Market Segmentations

3.3.  Overview of Key Market Players

3.4.  Overview of Key Regions/Countries

3.5.  Overview of Market Drivers, Challenges, Trends

4.    Impact of COVID-19 on United States Thermal Spray Coatings Market

5.    United States Thermal Spray Coatings Market Outlook

5.1.  Market Size & Forecast

5.1.1.     By Value

5.2.  Market Share & Forecast

5.2.1.     By Material (Ceramic Oxide, Carbides, Metals, Polymer, Others)

5.2.2.     By End User Industry (Automotive, Aerospace, Energy & Power, Electronics, Oil and Gas, Others)

5.2.3.     By Region

5.2.4.     By Company (2022)

5.3.  Market Map

6.    West United States Thermal Spray Coatings Market Outlook

6.1.  Market Size & Forecast

6.1.1.     By Value

6.2.  Market Share & Forecast

6.2.1.     By Material

6.2.2.     By End User Industry

7.    Northeast United States Thermal Spray Coatings Market Outlook

7.1.  Market Size & Forecast

7.1.1.     By Value

7.2.  Market Share & Forecast

7.2.1.     By Material

7.2.2.     By End User Industry

8.    Midwest United States Thermal Spray Coatings Market Outlook

8.1.  Market Size & Forecast

8.1.1.     By Value

8.2.  Market Share & Forecast

8.2.1.     By Material

8.2.2.     By End User Industry

9.    South United States Thermal Spray Coatings Market Outlook

9.1.  Market Size & Forecast

9.1.1.     By Value

9.2.  Market Share & Forecast

9.2.1.     By Material

9.2.2.     By End User Industry

9.3.  Drivers

9.4.  Challenges

10.  Market Trends & Developments

10.1.              Recent Developments

10.2.              Product Launches

10.3.              Mergers & Acquisitions

11.  United States Thermal Spray Coatings Market: SWOT Analysis

12.  Porter’s Five Forces Analysis

12.1.              Competition in the Industry

12.2.              Potential of New Entrants

12.3.              Power of Suppliers

12.4.              Power of Customers

12.5.              Threat of Substitute Product

13.  PESTLE Analysis

14.  Competitive Landscape

14.1.              APS Materials Inc

14.1.1.  Business Overview

14.1.2.  Company Snapshot

14.1.3.  Products & Services

14.1.4.  Financials (As Reported)

14.1.5.  Recent Developments

14.2.              ASB Industries Inc.

14.3.              Bodycote PLC

14.4.              Chromalloy Gas Turbine LLC

14.5.              Eurocoating SpA

14.6.              FM Industries Inc.

14.7.              FW Gartner Thermal Spraying (Curtis-Wright)

14.8.              Kennametal Inc.

14.9.              Oerlikon Metco

14.10.            Praxair S.T. Technology, Inc.

15.  Strategic Recommendations

16.  About Us & Disclaimer

Figures and Tables

Frequently asked questions


The market size of the United States Thermal Spray Coatings Market was estimated to be USD 1.52 billion in 2022.


APS Materials Inc, ASB Industries Inc., Bodycote PLC, Chromalloy Gas Turbine LLC, Eurocoating SpA, FM Industries Inc., FW Gartner Thermal Spraying (Curtis-Wright), Kennametal Inc., Oerlikon Metco, Praxair S.T. Technology, Inc are the major key players in the United States Thermal Spray Coatings Market.


Technological Complexity, High Initial Investment are the major challenges which can slow down the growth of United States Thermal Spray Coatings Market.


Increasing Demand from End-Use Industries and Rising Popularity of High-Performance Coatings are the major drivers for the United States Thermal Spray Coatings Market.


Sakshi Bajaal

Business Consultant
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