The U.S. thermal spray coatings market size was exhibited at USD 2.65 billion in 2023 and is projected to hit around USD 3.96 billion by 2033, growing at a CAGR of 4.11% during the forecast period 2024 to 2033.
| Report Coverage | Details |
| Market Size in 2024 | USD 2.76 Billion |
| Market Size by 2033 | USD 3.96 Billion |
| Growth Rate From 2024 to 2033 | CAGR of 4.11% |
| Base Year | 2023 |
| Forecast Period | 2024-2033 |
| Segments Covered | Material, Technology, Application |
| Market Analysis (Terms Used) | Value (US$ Million/Billion) or (Volume/Units) |
| Key Companies Profiled | OC Oerlikon Management AG; Praxair S.T. Technologies Inc.; Chromalloy Gas Turbine LLC; Kennametal Inc.; TOCALO Co. Ltd.; APS Materials Inc.; ASB Industries Inc.; Bodycote PLC; Eurocoating SpA; FM Industries Inc. |
This expansion is driven by several key factors, including increasing demand for performance-enhanced components in critical industries like aerospace and automotive, growing adoption of thermal spray coatings in medical devices for improved wear resistance and longevity, and ongoing advancements in material science.
The U.S. thermal spray coatings market accounted for a share of 23.6% of the global thermal spray coatings market revenue in 2023. Stringent environmental regulations, such as those stated by the EPA, can limit the application of alternative technologies like chrome plating, a process well-established for its generation of carcinogenic by-products. This creates a market opportunity for thermal spray coatings as a more sustainable alternative. For instance, regulations like the Restriction of Hazardous Substances (RoHS) in the U.S. restrict certain hazardous materials in products, pushing manufacturers towards thermal spray coatings that can achieve similar functionalities with less restricted materials.
The ceramics segment accounted for the largest revenue share of 32.1% in 2023. Ceramic coatings are known for their exceptional hardness, wear resistance, and thermal insulation properties. They find extensive applications in gas turbines, aerospace components, and industrial machinery. The projected growth for ceramics is robust, driven by increased demand from sectors, such as power generation, automotive, and medical devices. As industries seek improved performance and durability, ceramics remain a key choice for thermal spray coatings.
Abradables is another noteworthy segment, with a predicted CAGR of 5.4% from 2024 to 2033. These coatings are designed to be sacrificial, allowing them to wear away gradually during operation. They are commonly used in compressor seals, creating a tight seal while minimizing wear on adjacent components. The aerospace industry, in particular, benefits from abradables due to their ability to reduce clearance gaps and enhance engine efficiency.
The plasma spray segment dominated the market with a revenue share of 36.4% in 2023. This well-established technology is a versatile workhorse, offering a mature solution for various applications. It excels in wear and corrosion protection, thermal insulation, and surface modification. Plasma spray's popularity is attributed to its ability to deposit a wide range of materials with precise control over the coating's properties, thereby making it a dependable choice across numerous industries.
Cold spray is expected to be the fastest-growing segment from 2024 to 2033. This innovative technology offers distinct advantages, including minimal heating of the substrate, reduced oxidation, and the ability to deposit materials that are sensitive to high temperatures. These attributes make cold spray an attractive option for applications in automobile, aerospace, and even the biomedical field. As research and development continue, cold spray is poised for further growth and wider adoption in the U.S. thermal spray coatings market.
The aerospace segment dominated the market with a share of 33.2% in 2023. Thermal spray coatings play a vital role in the aerospace sector as they help enhance performance, improve wear resistance, and protect against extreme temperatures. These coatings benefit aircraft engines, turbine blades, and components exposed to high-velocity environments. As air travel continues to grow, the demand for thermal spray coatings in the aerospace sector is expected to increase in the coming years.
The oil and gas segment is projected to experience the fastest CAGR of 6.0% from 2024 to 2033. Thermal spray coatings find extensive use in this sector for protecting equipment exposed to harsh conditions, such as corrosion, erosion, and high temperatures. Pipelines, valves, drilling tools, and offshore platforms benefit from these coatings, extending their lifespan and reducing maintenance costs. As the energy industry seeks efficiency and durability, the adoption of thermal spray coatings in oil and gas applications continues to rise.
This report forecasts revenue growth at country levels and provides an analysis of the latest industry trends in each of the sub-segments from 2021 to 2033. For this study, Nova one advisor, Inc. has segmented the U.S. thermal spray coatings market
Material
Technology
Application
Chapter 1 Thermal Spray Coatings Market: Methodology and Scope
1.1 Market Segmentation & Scope
1.2 Market Definition
1.3 Information Procurement
1.3.1 Purchased Database
1.3.2 Internal Database
1.4 Information analysis
1.5 Market formulation & data visualization
1.6 Data validation & publishing
1.6.1 Research scope and assumptions
1.6.2 List to Data Sources
Chapter 2 Thermal Spray Coatings Market: Executive Summary
2.1 Market Snapshot
2.2 Segment Snapshot
2.3 Competitive Landscape Snapshot
Chapter 3 Thermal Spray Coatings Market: Variables, Trends & Scope
3.1 Market Lineage Outlook
3.1.1 Parent Market Outlook
3.2 Industry Value Chain Analysis
3.3 Manufacturing/Technology Trends
3.4 Sales Channel Analysis
3.5 Price Trend Analysis
3.5.1 Factors influencing prices
3.6 Regulatory Framework (Standards and Compliances, Approvals, Policies)
3.7 Market Dynamics
3.7.1 Market Driver Analysis
3.7.2 Market Restraint ANalysis
3.7.3 Market Challenge Analysis
3.7.4 Market Opportunities Analysis
3.8 Industry Analysis Tools
3.8.1 PORTERs Analysis
3.8.2 Macroeconomic Analysis- PESTLE Analysis
Chapter 4 Thermal Spray Coatings Market: Supplier Portfolio Analysis
4.1 List of Raw Material Suppliers
4.2 Raw Material Trends
4.3 Portfolio Analysis/ Kraljic Matrix
4.4 Engagement Model
4.5 Negotiation Strategies
4.6 Best Sourcing Practices
Chapter 5 Thermal Spray Coatings Market: Material Estimates & Trend Analysis
5.1 Material Movement Analysis & Market Share, 2024 & 2033
5.2 Thermal Spray Coatings Market Estimates & Forecast, by Material (USD Million)
5.2.1 Metals
5.2.1.1 Thermal Spray Coatings Market Estimates and Forecasts, in Metals, 2021 - 2033 (USD Million)
5.2.2 Ceramics
5.2.2.1 Thermal Spray Coatings Market Estimates and Forecasts, in Ceramics 2021 - 2033 (USD Million)
5.2.3 Intermetallics
5.2.3.1 Thermal Spray Coatings Market Estimates and Forecasts, in Intermetallic 2021 - 2033 (USD Million)
5.2.4 Polymers
5.2.4.1 Thermal Spray Coatings Market Estimates and Forecasts, in Polymers 2021 - 2033 (USD Million)
5.2.5 Carbides
5.2.5.1 Thermal Spray Coatings Market Estimates and Forecasts, in Carbides 2021 - 2033 (USD Million)
5.2.6 Abradables
5.2.6.1 Thermal Spray Coatings Market Estimates and Forecasts, in Abradable 2021 - 2033 (USD Million)
5.2.7 Others
5.2.7.1 Thermal Spray Coatings Market Estimates and Forecasts, in Others 2021 - 2033 (USD Million)
Chapter 6 Thermal Spray Coatings Market: Technology Estimates & Trend Analysis
6.1 Technology Movement Analysis & Market Share, 2024 & 2033
6.2 Thermal Spray Coatings Market Estimates & Forecast, by Application (USD Million)
6.2.1 Cold Spray
6.2.1.1 Thermal Spray Coatings Market Estimates and Forecasts, in Cold spray, 2021 - 2033 (USD Million)
6.2.2 Flame Spray
6.2.2.1 Thermal Spray Coatings Market Estimates and Forecasts, in Flame spray 2021 - 2033 (USD Million)
6.2.3 Plasma Spray
6.2.3.1 Thermal Spray Coatings Market Estimates and Forecasts, in Plasma spray 2021 - 2033 (USD Million)
6.2.4 HVOF
6.2.4.1 Thermal Spray Coatings Market Estimates and Forecasts, in HVOF 2021 - 2033 (USD Million)
6.2.5 Electric Arc Spray
6.2.5.1 Thermal Spray Coatings Market Estimates and Forecasts, in Electric arc spray 2021 - 2033 (USD Million)
6.2.6 Others
6.2.6.1 Thermal Spray Coatings Market Estimates and Forecasts, in Others 2021 - 2033 (USD Million)
Chapter 7 Thermal Spray Coatings Market: Application Estimates & Trend Analysis
7.1 Application Movement Analysis & Market Share, 2024 & 2033
7.2 Application Market Estimates & Forecast, by Application (USD Million)
7.2.1 Aerospace
7.2.1.1 Thermal Spray Coatings Market Estimates and Forecasts, in Aerospace, 2021 - 2033 (USD Million)
7.2.2 Industrial Gas Turbine
7.2.2.1 Thermal Spray Coatings Market Estimates and Forecasts, in Industrial Gas Turbine 2021 - 2033 (USD Million)
7.2.3 Automotive
7.2.3.1 Thermal Spray Coatings Market Estimates and Forecasts, in Automotive 2021 - 2033 (USD Million)
7.2.4 Medical
7.2.4.1 Thermal Spray Coatings Market Estimates and Forecasts, in Medical 2021 - 2033 (USD Million)
7.2.5 Printing
7.2.5.1 Thermal Spray Coatings Market Estimates and Forecasts, in Printing 2021 - 2033 (USD Million)
7.2.6 Oil & gas
7.2.6.1 Thermal Spray Coatings Market Estimates and Forecasts, in Oil & gas 2021 - 2033 (USD Million)
7.2.7 Steel
7.2.7.1 Thermal Spray Coatings Market Estimates and Forecasts, in Steel 2021 - 2033 (USD Million)
7.2.8 Pulp & Paper
7.2.8.1 Thermal Spray Coatings Market Estimates and Forecasts, in Pulp & Paper 2021 - 2033 (USD Million)
7.2.9 Others
7.2.9.1 Thermal Spray Coatings Market Estimates and Forecasts, in Others 2021 - 2033 (USD Million)
Chapter 8 Thermal Spray Coatings Market: Regional Estimates & Trend Analysis
8.1 Thermal Spray Coatings Market: Regional Outlook
8.2 North America
8.2.1 North america Thermal Spray Coatings Market Estimates & Forecasts, 2021 - 2033 (USD Million)
8.2.2 U.S.
8.2.2.1 Key country dynamics
8.2.2.2 U.S. Thermal Spray Coatings Market Estimates & Forecasts, 2021 - 2033 (USD Million)
8.2.3 Canada
8.2.3.1 Key country dynamics
8.2.3.2 Canada Thermal Spray Coatings Market Estimates & Forecasts, 2021 - 2033 (USD Million)
8.2.4 Mexico
8.2.4.1 Key country dynamics
8.2.4.2 Mexico Thermal Spray Coatings Market Estimates & Forecasts, 2021 - 2033 (USD Million)
8.3 Europe
8.3.1 Europe Thermal Spray Coatings Market Estimates & Forecasts, 2021 - 2033 (USD Million)
8.3.2 Germany
8.3.2.1 Key country dynamics
8.3.2.2 Germany Thermal Spray Coatings Market Estimates & Forecasts, 2021 - 2033 (USD Million)
8.3.3 UK
8.3.3.1 Key country dynamics
8.3.3.2 UK Thermal Spray Coatings Market Estimates & Forecasts, 2021 - 2033 (USD Million)
8.3.4 France
8.3.4.1 Key country dynamics
8.3.4.2 France Thermal Spray Coatings Market Estimates & Forecasts, 2021 - 2033 (USD Million)
8.3.5 Finland
8.3.5.1 Key country dynamics
8.3.5.2 Finland Thermal Spray Coatings Market Estimates & Forecasts, 2021 - 2033 (USD Million)
8.3.6 Sweden
8.3.6.1 Key country dynamics
8.3.6.2 Sweden Thermal Spray Coatings Market Estimates & Forecasts, 2021 - 2033 (USD Million)
8.3.7 Denmark
8.3.7.1 Key country dynamics
8.3.7.2 Denmark Thermal Spray Coatings Market Estimates & Forecasts, 2021 - 2033 (USD Million)
8.4 Asia Pacific
8.4.1 Asia Pacific Thermal Spray Coatings Market Estimates & Forecasts, 2021 - 2033 (USD Million)
8.4.2 China
8.4.2.1 Key country dynamics
8.4.2.2 China Thermal Spray Coatings Market Estimates & Forecasts, 2021 - 2033 (USD Million)
8.4.3 India
8.4.3.1 Key country dynamics
8.4.3.2 India Thermal Spray Coatings Market Estimates & Forecasts, 2021 - 2033 (USD Million)
8.4.4 Japan
8.4.4.1 Key country dynamics
8.4.4.2 Japan Thermal Spray Coatings Market Estimates & Forecasts, 2021 - 2033 (USD Million)
8.4.5 Australia
8.4.5.1 Key country dynamics
8.4.5.2 Australia Thermal Spray Coatings Market Estimates & Forecasts, 2021 - 2033 (USD Million)
8.4.6 Thailand
8.4.6.1 Key country dynamics
8.4.6.2 Thailand Thermal Spray Coatings Market Estimates & Forecasts, 2021 - 2033 (USD Million)
8.4.7 Malaysia
8.4.7.1 Key country dynamics
8.4.7.2 Malaysia Thermal Spray Coatings Market Estimates & Forecasts, 2021 - 2033 (USD Million)
8.5 Central & South America
8.5.1 Central & South America Thermal Spray Coatings Market Estimates & Forecasts, 2021 - 2033 (USD Million)
8.5.2 Brazil
8.5.2.1 Key country dynamics
8.5.2.2 Brazil Thermal Spray Coatings Market Estimates & Forecasts, 2021 - 2033 (USD Million)
8.5.3 Argentina
8.5.3.1 Key country dynamics
8.5.3.2 Argentina Thermal Spray Coatings Market Estimates & Forecasts, 2021 - 2033 (USD Million)
8.6 Middle East & Africa
8.6.1 Middle East & Africa Thermal Spray Coatings Market Estimates & Forecasts, 2021 - 2033 (USD Million)
8.6.2 Saudi Arabia
8.6.2.1 Key country dynamics
8.6.2.2 Saudi Arabia Thermal Spray Coatings Market Estimates & Forecasts, 2021 - 2033 (USD Million)
8.6.3 UAE
8.6.3.1 Key country dynamics
8.6.3.2 UAE Thermal Spray Coatings Market Estimates & Forecasts, 2021 - 2033 (USD Million)
Chapter 9 Competitive Landscape
9.1 Recent Developement
9.2 Key Company/Competition Categorization
9.3 List of key companies, by region
9.4 List of key companies, by technology/product
9.4.1 Identification of potential customers
9.4.1.1 Competitive Dashboard Analysis
9.5 Company Profiles
9.5.1 Praxair Surface Technologies, Inc.
9.5.2 Arkema
9.5.3 Höganäs AB
9.5.4 H.C. Starck Inc.
9.5.5 Castolin Eutectic
9.5.6 Wall Colmonoy Corporation
9.5.7 Powder Alloy Corporation
9.5.8 Saint-Gobain S.A.
9.5.9 Carpenter Technology Corporation
9.5.10 Fujimi Incorporated
9.5.11 Durum Verschleiss-Schutz GmbH
9.5.12 Montreal Carbide Co. Ltd.
9.5.13 Kennametal Stellite
9.5.14 Oerlikon Metco
9.5.15 AMT AG
9.5.16 GTV Verschleißschutz GmbH (GTV Wear Protection GmbH)
Cross-segment Market Size and Analysis for Mentioned Segments
Additional Company Profiles
(Upto 5 With No Cost)
Additional Countries (Apart
From Mentioned Countries)
Country/Region-specific Report
Go To Market Strategy
Region Specific Market DynamicsRegion Level Market Share Import Export AnalysisProduction AnalysisOthers