Thermal Spray Coatings Market Size, Share & COVID-19 Impact Analysis, By Material (Ceramic, Metal & Alloy, Polymer, Intermetallic, and Others), By Technology (Flame Spray, High-Velocity Oxygen Fuel (HVOF) Spray, Electric Arc Spray, Plasma Spray, Cold Spray, and Others), By Application (Aerospace, Industrial Gas Turbine, Automotive, Medical, Paper & Printing, Oil & Gas, Steel, and Others), and Regional Forecast, 2024-2032

The global thermal spray coatings market size was USD 10.23 billion in 2019 and is projected to reach USD 17.63 billion by 2027 while exhibiting a CAGR of 7.8% during the forecast period.North America dominated the thermal spray coatings market with a market share of 31.45% in 2019.

The growing range of applications such as protection against wear and corrosion, thickness, electrical resistance, and low toxic gas emissions are expected to drive the market. The growth in the demand for thermal spray is due to the rise in the use of spraying processes from aerospace, automotive, and other industries. The adoption of such coatings in biomedicine and surgical equipment can effectively enhance equipment wear resistance and facilitate the biocompatibility of prostheses and dental implants. This is anticipated to further boost the market.

Non-availability of Raw Material Impacted Vertical End-use Industries

The basic processes of fabrication such as thermal spraying have been affected since the end of 2019. The manufacturing sector faces significant disruption in the supply chain. Moreover, the COVID-19 outbreak has brought about a dramatic decline in new orders. In the short term, these factors are projected to have a negative effect on the demand on the market.

Throughout the pandemic, vertical end-user industries will face significant challenges in sourcing raw materials and retaining supply, which will influence demand in the short term. The implementation of thermal spray technology in the manufacture of medical devices, however, will help to partially mitigate the economic loss during the crisis. Most companies in the manufacturing sector are prepared for the COVID-19 effect on their operations. Factors such as reduced spending, low oil prices, and problems with cash flow are still major issues.

LATEST TRENDS

Increasing Use of Thermal Spray Coatings in the Medical Sector to Propel Demand

For different purposes, various thermal spraying processes have been widely applied on medical devices such as biological binding, surface roughening, and resemblance in chemical composition to bone minerals. In general, the U.S. Food and Drug Administration (FDA) requires a pre-market review of the coated product to bring a thermal spray coated product into the U.S. market. Although various thermal spray technologies and materials have been used for coatings on medical devices, FDA commonly observed this spraying process on orthopedic devices include hydroxyapatite (HA) and plasma-sprayed titanium (Ti) coatings as well as dual Ti / HA coatings. The coated tools are mainly metals such as Ti alloy, an alloy of cobalt-chrome, alloys of stainless steel and some polymers e.g., polyether ketone.

The standards organizations (e.g., ISO and ASTM) have also established various materials and testing criteria for these coatings, some of which are accepted by the FDA. In the biomedical and medical device industries, the use of thermal coatings can help enhance their abrasion resistance and biocompatibility, as well as better implant dentures. Thermal coatings are corrosion resistant and biocompatible for the biomedical industry, so they are highly suitable for use as bioceramic coatings in implant manufacturing. The market is expected to be driven by strong operations in the medical sector.

DRIVING FACTORS

Growing Preference for Driving the Thermal Spray Coatings over Chrome Plating to Aid Growth

Strong chrome plating has been a successful solution for the industry for many years owing to its oxidation, corrosion resistance, tear, and dimensional reclamation properties. It can be implemented at a reasonable cost per surface area unit, but it does have limitations on component size, thickness build-up, and performance in operation in some situations.  The growing environmental concerns and the stringent regulations enforced on the chrome plating process and disposal of its by-products, along with increased costs are driving the demand for the thermal type of spray coatings. 

It has thus become important for the industry to find alternative processes that give hard chrome plating comparable characteristics but without the resulting hazards. Thermal spraying technology is slowly offering a viable alternative to this method, which may provide complementary processes for parts safety which reclamation to the chrome plating industry. The thermal coatings are much more durable than chrome plating. Additionally, chrome plating has micro-cracking within the layer of plating which allows high or low pH corrosive agents to penetrate the plating and attack the substrate. The adjacent photomicrograph can show micro-cracking.

The resistance of the thermal coatings to fatigue is much higher than that of chrome plating. Since high-velocity oxygen fuel (HVOF) coatings impart a compressive load to the substratum, component life is actually increased by resisting crack initiation against fatigue failure. Chrome plating introduces tensile loading onto the surface of the substratum which initiates crack formation and may result in premature failure. End-use industries shifting from chrome plating to thermal spraying are anticipated to drive the growth of the market.

RESTRAINING FACTORS

Formation of Globular Pores by Thermal Spray Coatings to Hinder the Market Growth

Thermal spray coatings often produce certain defects such as pores, mostly globular formed during the process and exploded particles and cracks are created during the relaxation of residual stresses. Unmolten or partially melted particles formed cause the worst defects. The cracks appear as micro-cracks inside splats, and micro-cracks running especially at their interfaces through layered splats and appearing to initiate interconnected porosities. Additionally, when the spraying process is conducted in air, oxidation of heated or completely melted particles may occur throughout the flight as well as that of splats, and successive passes during coating forming.

The coatings are more or less transparent depending on the spray conditions and sprayed materials and must be sealed by suitable means for some applications.

Finally, another source of defects in the angle of the particle impact that reduces the normal velocity of the impact resulting in elongated splats. Depending on the particle and substrate materials, spraying with an angle above a certain value can encourage splashing even on substrates preheated above the so-called transition temperature.

SEGMENTATION

By Material Analysis

Ceramic Segment to Hold a Significant Share of the Market

Based on material, the market is segmented into ceramic, metal & alloy, polymer, intermetallic, and others.

The ceramic segment held a major revenue share of the market due to the growing use of ceramic mostly in the biomedicine industry. This is anticipated to have a positive impact on the market. The segment is further expected to be the highest contributor to revenue owing to the increasing demand from manufacturing, automotive and aerospace applications. The growing demand for ceramics is due to its properties such as heat resistance and corrosion resistance. Moreover, ceramics are cost-effective which is likely promoting the demand for this material.

Metal & alloy and polymer are commonly used on the substratum surface, which ensures that the products have a longer service life under harsh operating conditions. The wide range of microstructures, film deposition speed, and raw material applicability make use of such metal materials to render coatings profitable.

Intermetallic material is mostly used in steam generators, coal-fired gas turbines, and others due to various advantages such as high melting point, low density, high thermal conductivity, and hot corrosion resistance. The automobile, petrochemical, and aerospace & defense industries are paying considerable attention to polymers. The polymer is used to shield the surface from harsh chemical conditions, rust, and humidity.

By Technology Analysis

Flame Spray to Emerge as Leading Segment Owing to Production of High-Quality Metal Coatings

In terms of technology, the market is segmented into flame spray, high-velocity oxygen fuel (HVOF) spray, electric arc spray, plasma spray, cold spray, and others.

The flame spray segment constituted the primary share of the market. The method of flame spraying uses a flame of oxy-acetylene to add thermal spray coating. The heat from the flame dissolves the coating material and the compressed air propels it onto the sprayed product. The flame spray can be used to add high-quality metal coatings to protect against corrosion.

HVOF technology can be used in the manufacturing of medical dental implants. The expansion of this sector would have a positive impact on demand growth during the forecast period. The thickness of the coating is easily monitored, so the process can even be used to restore the dimensions of a worn part or portion that is improperly machined.

Arc spraying is typically the most economical thermal spray process for the application of metal coatings resistant to corrosion, including zinc, aluminum, and its alloys. The energy costs are lower and the rates of production are higher than the alternative approaches such as flame spraying. Plasma spray technology will make significant progress during the forecast period due to its large application on a variety of materials and surfaces.

By Application Analysis

Aerospace Segment to Lead Due to Growing Demand for Corrosion-resistant Coatings

On the basis of application, the market is classified into aerospace, industrial gas turbine, automotive, medical, paper & printing, oil & gas, steel, and others.

The growing demand for corrosion-resistant coatings is projected to be a key driving force for market growth in the aerospace and automotive industries. The different sections of aircraft need high-strength and wear-resistant coatings that should have the ability to withstand high temperatures above 800°C. Factors such as wear and corrosion resistance reduced emissions, and greater thickness characteristics generate strong demand for applications in the aerospace industry.

With industrialization growth and government support for the automotive manufacturing industry, India will have a higher demand for automobiles. With the government's implementation of the "Make in India" scheme, it would effectively advance domestic car and parts production in India.

Strict guidelines released by the Environmental Protection Agency (EPA) and AFSP have facilitated the implementation of thermal spraying in the automotive industry, with the enhancement of customer health and environmental awareness. In addition to this, the market for smart, environmentally sustainable, and fuel-efficient vehicles are driven by changing customer preference, technological advancements, and stringent climate policies.

Industrial gas turbines accounted for a significant share of the market. The market is expected to increase in the future with the continuous expansion of applications such as ships, trains, tanks, helicopters, and motorcycles. In the biomedical and medical device industries, the use of thermal spraying can help enhance their abrasion resistance and biocompatibility, as well as better implant dentures.

REGIONAL INSIGHTS

The thermal spray coatings market size in North America stood at USD 3,217.6 million in 2019. North America dominated the market and is likely to maintain the trend during the forecast period owing to the expanding range of applications such as engineering coatings, wear-resistant coatings, automotive, aviation, biomedicine, food processing, semiconductors, electronics, and energy fields that is expected to fuel demand. The growing oil and gas industry particularly in North America and the Middle East & Africa is expected to drive the market during the forecast period. The aviation industry is progressing and has gradually increased the demand for the product. This is anticipated to boost the market.

In order to meet tough environmental standards, especially in North America, the consumer trend from hard chrome coatings to thermal spraying is anticipated to be a major market driver.

The increasing R&D investment in the pharmaceutical industry in Europe is projected to boost demand. Russia is experiencing a huge demand for crude oil and natural gas, combined with the rising deployment of improved oil recovery by manufacturers that are expected to fuel the market growth.

The civil aviation sector is experiencing continual growth owing to the high consumer disposable income especially in the Asia Pacific region, where China and India are the main pillars. This is projected to have a positive on the market during the forecast period. The rapid growth of industrialization led to the influx of a large number of automakers, especially in China and India. Industries in the Asia Pacific are expected to witness significant growth due to strong growth in the medical and oil & gas industries, especially in the natural gas industries of India and China.

The increasing production from the oil & gas industry in the Middle East & Africa is likely to drive the market. Thus oil & gas equipment requires maintenance and the benefits of using thermal spraying are low harmful gas emissions, thickness, corrosion and wear safety, and electrical resistance.

Brazil is one of the leading industrial jet producers and produces a number of aerospace, including military aircraft, turboprop aircraft, recreational aircraft, helicopters, agricultural aircraft, and other general aviation aircraft. Increasing thermal spray applications in the aerospace industries are expected to boost demand.

KEY INDUSTRY PLAYERS

Strategic Planning Adopted by Companies to Strengthen their Market Share

The market is defined by the presence of different small and medium-sized companies that cater to global demands. Integration through the value chain stages results in a continuous supply of raw materials, as well as low cost of production. A few companies are focusing on R&D initiatives to improve their product requirements and customer penetration that is expected to further increase demand for the market during the forecast period. The report offers an in-depth competitive landscape with their business profiles, key market strategies, and recent innovations of these key players in the global market.

LIST OF KEY COMPANIES PROFILED:

• Praxair S.T. Technology, Inc. (U.S.)


• Bodycote (UK)


• Oerlikon Metco (Switzerland)


• Surface Technology UK (UK)


• H.C. Starck GmbH (Germany)


• F.W. Gartner Thermal Spraying (U.S.)


• Höganäs AB (Sweden)


• Metallisation Limited (UK)


• Flame Spray SpA (Italy)


• BryCoat Inc. (U.S.)


• Carpenter Technology Corporation (U.S.)


• A&A Thermal Spray Coatings (U.S.)


• ASB Industries, Inc. (U.S.)


• Polymet Corporation (U.S.)


• TST Coatings Inc. (U.S.)


• Other Key Players

KEY INDUSTRY DEVELOPMENTS:

• July 2019 – Oerlikon Metco announced the signing of an agreement to acquire AMT AG, a Swiss company that designs and constructs integrated thermal spray coating systems. The acquisition is in line with Oerlikon's strategy to concentrate and broaden its surface solution technologies while growing consumer accessibility for business applications and services.

REPORT COVERAGE

The thermal spray coatings market research report provides a detailed analysis of the market and focuses on crucial aspects such as leading companies, products, and applications. Also, the report offers insights into market trends and highlights vital industry developments. In addition to the factors mentioned above, the report encompasses various factors that have contributed to the growth of the market over recent years. The report further includes historical data & forecasts revenue growth at global, regional, and country levels, and analyzes the latest market dynamics and opportunities in the industry.

Report Scope & Segmentation