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Thermal Spray Coatings Market Size, Share & Trends Analysis Report by Technology (Coldspray, Flamespray, Plasma Spray, HVOF, Electric arc spray), Material, Application, and Region with Growth Forecasts, 2026-2033

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    Report

  • 128 Pages
  • December 2025
  • Region: Global
  • Grand View Research
  • ID: 4479760
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. The report 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
  • Europe
  • Asia-Pacific
  • Latin America
  • Middle East & Africa

Why You Should Buy This Report

  • Comprehensive Market Analysis: Gain detailed insights into the market across major regions and segments.
  • Competitive Landscape: Explore the market presence of key players.
  • Future Trends: Discover the pivotal trends and drivers shaping the future of the market.
  • Actionable Recommendations: Utilize insights to uncover new revenue streams and guide strategic business decisions.

This report addresses:

  • Market intelligence to enable effective decision-making
  • Market estimates and forecasts from 2018 to 2030
  • Growth opportunities and trend analyses
  • Segment and regional revenue forecasts for market assessment
  • Competition strategy and market share analysis
  • Product innovation listings for you to stay ahead of the curve

Table of Contents

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 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
List of Tables
Table 1 List of Raw Material Suppliers
Table 2 U.S. macro-economic outlay
Table 3 Canada macro-economic outlay
Table 4 Mexico macro-economic outlay
Table 5 Germany macro-economic outlay
Table 6 UK macro-economic outlay
Table 7 France macro-economic outlay
Table 8 Italy macro-economic outlay
Table 9 Russia macro-economic outlay
Table 10 Spain macro-economic outlay
Table 11 China macro-economic outlay
Table 12 India macro-economic outlay
Table 13 Japan macro-economic outlay
Table 14 Japan macro-economic outlay
Table 15 South Korea macro-economic outlay
Table 16 Malaysia macro-economic outlay
Table 17 Brazil macro-economic outlay
Table 18 Argentina macro-economic outlay
Table 19 Saudi Arabia-economic outlay
Table 20 South Africa macro-economic outlay
Table 21 Company Heat Map Analysis
Table 22 Financial Performance
Table 23 Product Benchmarking
Table 24 Key Companies Undergoing Expansions
Table 25 Key Companies Involved in Collaborations
Table 26 Key Companies Involved in Partnerships
Table 27 Key Companies Launching New Products
Table 28 List of Key Distributors/Channel Partners
List of Figures
Figure 1 Thermal Spray Coatings Market Segmentation & Scope
Figure 2 Information procurement
Figure 3 Data analysis models
Figure 4 Market formulation and validation
Figure 5 Data validating & publishing
Figure 6 Thermal Spray Coatings Market Snapshot
Figure 7 Thermal Spray Coatings Market Segment Snapshot
Figure 8 Thermal Spray Coatings Market Competitive Landscape Snapshot
Figure 9 Thermal Spray Coatings Market - Value Chain Analysis
Figure 10 Thermal Spray Coatings Market: Price Trend Analysis, 2018-2033 (USD/kg)
Figure 11 Thermal Spray Coatings Market Dynamics
Figure 12 Thermal Spray Coatings Market: PORTER’s Analysis
Figure 13 Thermal Spray Coatings Market: PESTLE Analysis
Figure 14 Thermal Spray Coatings Market: Portfolio Analysis/ Kraljic Matrix, by Raw Material
Figure 15 Thermal Spray Coatings Market Estimates & Forecasts, by Material: Key Takeaways
Figure 16 Thermal Spray Coatings Market Share, by Material, 2025 & 2033
Figure 17 Metal Thermal Spray Coating Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 18 Ceramic Thermal Spray Coating Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 19 Intermetallic Thermal Spray Coating Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 20 Polymers Thermal Spray Coating Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 21 Carbides Thermal Spray Coating Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 22 Arbadables Thermal Spray Coating Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 23 Others Thermal Spray Coating Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 24 Thermal Spray Coatings Market Estimates & Forecasts, by Technology: Key Takeaways
Figure 25 Thermal Spray Coatings Market Share, by Application, 2025 & 2033
Figure 26 Cold Spray Thermal Spray Coating Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 27 Flame Spray Thermal Spray Coating Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 28 Plasma Spray Thermal Spray Coating Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 29 High Velocity Oxy Fuel (HVOF) Thermal Spray Coating Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 30 Electric Arc Spray Thermal Spray Coating Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 31 Others Thermal spray coating Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 32 Thermal Spray Coatings Market Estimates & Forecasts, by Application: Key Takeaways
Figure 33 Thermal Spray Coatings Market Share, by Application, 2025 & 2033
Figure 34 Aerospace Thermal Spray Coating Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 35 Industrial Gas Turbine Thermal Spray Coating Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 36 Automotive Thermal Spray Coating Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 37 Medical Thermal Spray Coating Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 38 Printing Thermal Spray Coating Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 39 Oil & Gas Thermal Spray Coating Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 40 Steel Thermal Spray Coating Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 41 Oil & Gas Thermal Spray Coating Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 42 Others Thermal Spray Coating Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 43 Thermal Spray Coatings Market Revenue, by Region, 2025 & 2033 (USD Million)
Figure 44 North America Thermal Spray Coatings Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 45 U.S. Thermal Spray Coatings Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 46 Canada Thermal Spray Coatings Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 47 Mexico Thermal Spray Coatings Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 48 Europe Thermal Spray Coatings Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 49 Germany Thermal Spray Coatings Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 50 UK Thermal Spray Coatings Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 51 France Thermal Spray Coatings Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 52 Italy Thermal Spray Coatings Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 53 Spain Thermal Spray Coatings Market Estimates & Forecasts and Trend Analysis, 2018-2033 (USD Million)
Figure 54 RussiaThermal Spray Coatings Market Estimates & Forecasts and Trend Analysis, 2018-2033 (USD Million)
Figure 55 Asia-Pacific Thermal Spray Coatings Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 56 China Thermal Spray Coatings Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 57 India Thermal Spray Coatings Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 58 Japan Thermal Spray Coatings Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 59 Japan Thermal Spray Coatings Market Estimates & Forecasts and Trend Analysis, 2018-2033 (USD Million)
Figure 60 South Korea Thermal Spray Coatings Market Estimates & Forecasts and Trend Analysis, 2018-2033 (USD Million)
Figure 61 Malaysia Thermal Spray Coatings Market Estimates & Forecasts and Trend Analysis, 2018-2033 (USD Million)
Figure 62 Latin America Thermal Spray Coatings Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 63. Brazil Thermal Spray Coatings Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 64 Argentina Thermal Spray Coatings Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 65 Middle East & Africa Thermal Spray Coatings Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 66 Saudi Arabia Thermal Spray Coatings Market Estimates & Forecasts, 2018-2033 (USD Million)
Figure 67 South Africa Thermal Spray Coatings Market Estimates & Forecasts and Trend Analysis, 2018-2033 (USD Million)
Figure 68 Key Company/Competition Categorization
Figure 69 Key Strategy Mapping

Companies Mentioned

The companies profiled in this Thermal Spray Coatings market report include:
  • Linde PLC
  • Höganäs AB
  • H.C. Starck Inc.
  • Castolin Eutectic
  • Wall Colmonoy Corporation
  • Powder Alloy Corporation
  • MTC Industries and Research
  • Fujimi Incorporated
  • Oerlikon Metco
  • Kennametal Stellite
  • GTV Verschleißschutz GmbH
  • Flame Spray Inc.
  • HTS Coatings
  • Cincinnati Thermal Spray, Inc.
  • Bodycote
  • Chromalloy
  • Sulzer Ltd
  • Hannecard

Table Information