Thermal Spray Coatings Market Size, Share & Trends Analysis Report By Technology (Coldspray, Flamespray, Plasma Spray, HVOF, Electric arc spray), By Material, By Application, By Region, And Segment Forecasts, 2026 - 2033
Description
Thermal Spray Coatings Market Summary
The global thermal spray coatings market size was estimated at USD 11.29 billion in 2025 and is projected to reach USD 16.22 billion by 2033, growing at a CAGR of 4.7% from 2026 to 2033. The market growth depends on the use of thermal spray coatings in various end-use industries, including automotive, aerospace, medical, industrial gas turbines, printing, steel, and pulp & paper.
The rising use of gas turbines in helicopter engines, tanks, ships, and locomotives is expected to help augment the demand for thermal spray coatings due to their high temperature and corrosion resistance, which protects the parts against fire in high-temperature and moisture-laden conditions.
The properties provided by thermal spray coatings include wear resistance against abrasion, cavitation, and erosive forces, as well as chemical resistance, electrical insulation, and improved adhesion between the substrate and the top layer of components. The stringent regulations by the U.S. EPA, REACH, and OSHA regarding the curtailment of hard chrome plating, which produces a byproduct recognized as a carcinogen, influence the coating manufacturers to adopt sustainable solutions that can further propel the market growth in various end-use industries.
This is attributed to the high demand from power generation plants for industrial gas turbines, which are expected to witness a surge in gas turbine demand due to the policy transition of the U.S. government toward replacing coal with natural gas for electricity generation. According to the Rural Health Information Hub, there are currently 46 million adults over the age of 65 years living in the U.S., which is expected to grow to 90 million by 2050. The rising geriatric population and improved healthcare services in the U.S. are expected to drive the market for orthopedic implants required in knee cap replacement surgery, and are anticipated to grow the market in the region.
Global Thermal Spray Coatings Market Report Segmentation
This report forecasts revenue growth at the global, regional, and country levels and provides an analysis of the latest trends in each of the sub-segments from 2018 to 2033. For this study, Grand View Research has segmented the global thermal spray coatings market report based on material, technology, application, and region:
The global thermal spray coatings market size was estimated at USD 11.29 billion in 2025 and is projected to reach USD 16.22 billion by 2033, growing at a CAGR of 4.7% from 2026 to 2033. The market growth depends on the use of thermal spray coatings in various end-use industries, including automotive, aerospace, medical, industrial gas turbines, printing, steel, and pulp & paper.
The rising use of gas turbines in helicopter engines, tanks, ships, and locomotives is expected to help augment the demand for thermal spray coatings due to their high temperature and corrosion resistance, which protects the parts against fire in high-temperature and moisture-laden conditions.
The properties provided by thermal spray coatings include wear resistance against abrasion, cavitation, and erosive forces, as well as chemical resistance, electrical insulation, and improved adhesion between the substrate and the top layer of components. The stringent regulations by the U.S. EPA, REACH, and OSHA regarding the curtailment of hard chrome plating, which produces a byproduct recognized as a carcinogen, influence the coating manufacturers to adopt sustainable solutions that can further propel the market growth in various end-use industries.
This is attributed to the high demand from power generation plants for industrial gas turbines, which are expected to witness a surge in gas turbine demand due to the policy transition of the U.S. government toward replacing coal with natural gas for electricity generation. According to the Rural Health Information Hub, there are currently 46 million adults over the age of 65 years living in the U.S., which is expected to grow to 90 million by 2050. The rising geriatric population and improved healthcare services in the U.S. are expected to drive the market for orthopedic implants required in knee cap replacement surgery, and are anticipated to grow the market in the region.
Global Thermal Spray Coatings Market Report Segmentation
This report forecasts revenue growth at the global, regional, and country levels and provides an analysis of the latest trends in each of the sub-segments from 2018 to 2033. For this study, Grand View Research has segmented the global thermal spray coatings market report based on material, technology, application, and region:
- Material Outlook (Revenue, USD Million, 2018 - 2033)
- Metals
- Ceramics
- Intermetallics
- Polymers
- Carbides
- Abradables
- Others
- Technology Outlook (Revenue, USD Million, 2018 - 2033)
- Cold Spray
- Flame Spray
- Plasma Spray
- HVOF
- Electric Arc Spray
- Others
- Application Outlook (Revenue, USD Million, 2018 - 2033)
- Aerospace
- Industrial Gas Turbine
- Automotive
- Medical
- Printing
- Oil & Gas
- Steel
- Pulp & Paper
- Others
- Regional Outlook (Revenue, USD Million, 2018 - 2033)
- North America
- U.S.
- Canada
- Mexico
- Europe
- Germany
- UK
- France
- Italy
- Spain
- Russia
- Asia Pacific
- Japan
- China
- India
- South Korea
- Latin America
- Brazil
- Argentina
- Middle East & Africa
- Saudi Arabia
- South Africa
Table of Contents
128 Pages
- Chapter 1 Methodology and Scope
- 1.1 Market Segmentation & Scope
- 1.2 Market Definition
- 1.3 Information Procurement
- 1.3.1 Purchased Database
- 1.3.2 GVR’s 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 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 Paints & Coatings Market Outlook
- 3.2 Industry Value Chain Analysis
- 3.2.1 Raw Material Trends
- 3.2.2 Manufacturing/Technology Trends
- 3.2.3 Sales Channel Analysis
- 3.3 Regulatory Framework, by Region
- 3.4 Market Dynamics
- 3.4.1 Market Driver Analysis
- 3.4.2 Market Restraint Analysis
- 3.4.3 Market Challenge Analysis
- 3.4.4 Market Opportunities Analysis
- 3.5 Industry Analysis Tools
- 3.5.1 Porter's Analysis
- 3.5.2 Macroeconomic Analysis- PESTLE Analysis
- Chapter 4 Thermal Spray Coatings Market: Material Estimates & Trend Analysis
- 4.1 Material Movement Analysis & Market Share, 2025 & 2033
- 4.2 Thermal Spray Coatings Market Estimates & Forecast, by Material (USD Million)
- 4.2.1 Metals
- 4.2.1.1 Thermal Spray Coatings Market Estimates and Forecasts, in Metals, 2018 - 2033 (USD Million)
- 4.2.2 Ceramics
- 4.2.2.1 Thermal Spray Coatings Market Estimates and Forecasts, in Ceramics, 2018 - 2033 (USD Million)
- 4.2.3 Intermetallics
- 4.2.3.1 Thermal Spray Coatings Market Estimates and Forecasts, in Intermetallics, 2018 - 2033 (USD Million)
- 4.2.4 Polymers
- 4.2.4.1 Thermal Spray Coatings Market Estimates and Forecasts, in Polymers, 2018 - 2033 (USD Million)
- 4.2.5 Carbides
- 4.2.4.1 Thermal Spray Coatings Market Estimates and Forecasts, in Carbides, 2018 - 2033 (USD Million)
- 4.2.6 Abradables
- 4.2.6.1 Thermal Spray Coatings Market Estimates and Forecasts, in Abradables, 2018 - 2033 (USD Million)
- 4.2.7 Others
- 4.2.7.1 Thermal Spray Coatings Market Estimates and Forecasts, in Others, 2018 - 2033 (USD Million)
- Chapter 5 Thermal Spray Coatings Market: Technology Estimates & Trend Analysis
- 5.1 Technology Movement Analysis & Market Share, 2025 & 2033
- 5.2 Thermal Spray Coatings Market Estimates & Forecast, by Application (USD Million)
- 5.2.1 Cold Spray
- 5.2.1.1 Thermal Spray Coatings Market Estimates and Forecasts, in Cold Spray, 2018 - 2033 (USD Million)
- 5.2.2 Flame Spray
- 5.2.2.1 Thermal Spray Coatings Market Estimates and Forecasts, in Flame Spray, 2018 - 2033 (USD Million)
- 5.2.3 Plasma Spray
- 5.2.3.1 Thermal Spray Coatings Market Estimates and Forecasts, in Plasma Spray, 2018 - 2033 (USD Million)
- 5.2.4 HVOF
- 5.2.4.1 Thermal Spray Coatings Market Estimates and Forecasts, in HVOF, 2018 - 2033 (USD Million)
- 5.2.5 Electric Arc Spray
- 5.2.5.1 Thermal Spray Coatings Market Estimates and Forecasts, in Electric Arc Spray, 2018 - 2033 (USD Million)
- 5.2.6 Others
- 5.2.6.1 Thermal Spray Coatings Market Estimates and Forecasts, in Others, 2018 - 2033 (USD Million)
- Chapter 6 Thermal Spray Coatings Market: Application Estimates & Trend Analysis
- 6.1 Application Movement Analysis & Market Share, 2025 & 2033
- 6.2 Application Market Estimates & Forecast, by Application (USD Million)
- 6.2.1 Aerospace
- 6.2.1.1 Thermal Spray Coatings Market Estimates and Forecasts, in Aerospace, 2018 - 2033 (USD Million)
- 6.2.2 Industrial Gas Turbine
- 6.2.2.1 Thermal Spray Coatings Market Estimates and Forecasts, in Industrial Gas Turbine, 2018 - 2033 (USD Million)
- 6.2.3 Automotive
- 6.2.3.1 Thermal Spray Coatings Market Estimates and Forecasts, in Automotive, 2018 - 2033 (USD Million)
- 6.2.4 Medical
- 6.2.4.1 Thermal Spray Coatings Market Estimates and Forecasts, in Medical, 2018 - 2033 (USD Million)
- 6.2.5 Printing
- 6.2.5.1 Thermal Spray Coatings Market Estimates and Forecasts, in Printing, 2018 - 2033 (USD Million)
- 6.2.6 Oil & gas
- 6.2.6.1 Thermal Spray Coatings Market Estimates and Forecasts, in Oil & Gas, 2018 - 2033 (USD Million)
- 6.2.7 Steel
- 6.2.6.1 Thermal Spray Coatings Market Estimates and Forecasts, in Steel, 2018 - 2033 (USD Million)
- 6.2.8 Pulp & Paper
- 6.2.8.1 Thermal Spray Coatings Market Estimates and Forecasts, in Pulp & Paper, 2018 - 2033 (USD Million)
- 6.2.9 Others
- 6.2.9.1 Thermal Spray Coatings Market Estimates and Forecasts, in Others, 2018 - 2033 (USD Million)
- Chapter 7 Thermal Spray Coatings Market: Regional Estimates & Trend Analysis
- 7.1 Thermal Spray Coatings Market: Regional Outlook
- 7.2 North America
- 7.2.1 North america Thermal Spray Coatings Market Estimates & Forecasts, 2018 - 2033 (USD Million)
- 7.2.2 U.S.
- 7.2.2.1 Key country dynamics
- 7.2.2.2 U.S. Thermal Spray Coatings Market Estimates & Forecasts, 2018 - 2033 (USD Million)
- 7.2.3 Canada
- 7.2.3.1 Key country dynamics
- 7.2.3.2 Canada Thermal Spray Coatings Market Estimates & Forecasts, 2018 - 2033 (USD Million)
- 7.2.4 Mexico
- 7.2.4.1 Key country dynamics
- 7.2.4.2 Mexico Thermal Spray Coatings Market Estimates & Forecasts, 2018 - 2033 (USD Million)
- 7.3 Europe
- 7.3.1 Europe Thermal Spray Coatings Market Estimates & Forecasts, 2018 - 2033 (USD Million)
- 7.3.2 Germany
- 7.3.2.1 Key country dynamics
- 7.3.2.2 Germany Thermal Spray Coatings Market Estimates & Forecasts, 2018 - 2033 (USD Million)
- 7.3.3 UK
- 7.3.3.1 Key country dynamics
- 7.3.3.2 UK Thermal Spray Coatings Market Estimates & Forecasts, 2018 - 2033 (USD Million)
- 7.3.4 France
- 7.3.4.1 Key country dynamics
- 7.3.4.2 France Thermal Spray Coatings Market Estimates & Forecasts, 2018 - 2033 (USD Million)
- 7.3.5 Italy
- 7.3.5.1 Key country dynamics
- 7.3.5.2 Italy Thermal Spray Coatings Market Estimates & Forecasts, 2018 - 2033 (USD Million)
- 7.3.6 Russia
- 7.3.6.1 Key country dynamics
- 7.3.6.2 Russia Thermal Spray Coatings Market Estimates & Forecasts, 2018 - 2033 (USD Million)
- 7.3.7 Spain
- 7.3.7.1 Key country dynamics
- 7.3.7.2 Spain Thermal Spray Coatings Market Estimates & Forecasts, 2018 - 2033 (USD Million)
- 7.4 Asia Pacific
- 7.4.1 Asia Pacific Thermal Spray Coatings Market Estimates & Forecasts, 2018 - 2033 (USD Million)
- 7.4.2 China
- 7.4.2.1 Key country dynamics
- 7.4.2.2 China Thermal Spray Coatings Market Estimates & Forecasts, 2018 - 2033 (USD Million)
- 7.4.3 India
- 7.4.3.1 Key country dynamics
- 7.4.3.2 India Thermal Spray Coatings Market Estimates & Forecasts, 2018 - 2033 (USD Million)
- 7.4.4 Japan
- 7.4.4.1 Key country dynamics
- 7.4.4.2 Japan Thermal Spray Coatings Market Estimates & Forecasts, 2018 - 2033 (USD Million)
- 7.5.6 South Korea
- 7.5.6.1 Key country dynamics
- 7.5.6.2 South Korea Thermal Spray Coatings Market Estimates & Forecasts, 2018 - 2033 (USD Million)
- 7.5 Latin America
- 7.5.1 Latin America Thermal Spray Coatings Market Estimates & Forecasts, 2018 - 2033 (USD Million)
- 7.5.2 Brazil
- 7.5.2.1 Key country dynamics
- 7.5.2.2 Brazil Thermal Spray Coatings Market Estimates & Forecasts, 2018 - 2033 (USD Million)
- 7.5.3 Argentina
- 7.5.3.1 Key country dynamics
- 7.5.3.2 Argentina Thermal Spray Coatings Market Estimates & Forecasts, 2018 - 2033 (USD Million)
- 7.6 Middle East & Africa
- 7.6.1 Middle East & Africa Thermal Spray Coatings Market Estimates & Forecasts, 2018 - 2033 (USD Million)
- 7.6.2 Saudi Arabia
- 7.6.2.1 Key country dynamics
- 7.6.2.2 Saudi Arabia Thermal Spray Coatings Market Estimates & Forecasts, 2018 - 2033 (USD Million)
- 7.6.3 South Africa
- 7.6.3.1 Key country dynamics
- 7.6.3.2 South Africa Thermal Spray Coatings Market Estimates & Forecasts, 2018 - 2033 (USD Million)
- Chapter 8 Competitive Landscape
- 8.1 Recent Development & Impact Analysis
- 8.2 Financial performance
- 8.3 Company Heat Map Analysis
- 8.4 Key Company/Competition Categorization
- 8.5 Vendor Landscape
- 8.5.1 List of Raw Material Providers
- 8.5.2 List of End Users
- 8.6 Company Profiles
- 8.6.1 Linde PLC
- 8.6.2 Höganäs AB
- 8.6.3 H.C. Starck Inc.
- 8.6.4 Castolin Eutectic
- 8.6.5 Wall Colmonoy Corporation
- 8.6.6 Powder Alloy Corporation
- 8.6.7 MTC Industries and Research
- 8.6.8 Fujimi Incorporated
- 8.6.9 Oerlikon Metco
- 8.6.10 Kennametal Stellite
- 8.6.11 GTV Verschleißschutz GmbH
- 8.6.12 Flame Spray Inc.
- 8.6.13 HTS Coatings
- 8.6.14 Cincinnati Thermal Spray, Inc.
- 8.6.15 Bodycote
- 8.6.16 Chromalloy
- 8.6.17 Sulzer Ltd
- 8.6.18 Hannecard
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