The global thermal spray coatings market is estimated to be valued at USD 11.88 Bn in 2025 and is expected to reach USD 18.96 Bn by 2032, growing at a compound annual growth rate (CAGR) of 6.9% from 2025 to 2032.
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The growing infrastructure and construction industry is driving the demand for thermal spray coatings that provide protection against corrosion, abrasion, and high-temperatures. These coatings are ideal for applications in industries, such as aerospace, industrial gas turbines, automotive, and healthcare, where increased component performance and longevity are important. New product developments catering to requirements across different end-use industries will further aid the market expansion. Increasing R&D investments by key players to develop sustainable and environment-friendly thermal spray technologies will boost the adoption of these coatings.
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In terms of material, ceramics contributes 34.8% share of the market in 2025 owing to its superior thermal conductivity and corrosion resistance properties. Ceramic coatings like aluminum oxide and zirconium oxide are highly tolerant of high temperatures compared to other materials. They effectively resist heat transfer which makes them highly suitable for applications involving extreme operating temperatures like gas turbines, diesel engines, and furnace components. Ceramic coatings do not conduct electricity as well, providing vital insulation in these contexts. In addition, ceramic coatings are highly corrosion and wear resistant. The strength and durability of ceramic microstructures allow them to withstand abrasive environments and harsh chemicals found in industries like oil & gas, steel manufacturing, and pharmaceutical production. They protect metal substrates from degradation and prolong product lifecycles.
Ceramic coatings form hard, smooth surfaces that reduce friction and prevent galling, scoring or scratching. Their resistance to slurry erosion, and cavitation erosion fosters reliability in pumps, pipes, and hydro-turbine components. The bio-compatibility of certain ceramics like hydroxyapatite has also increased their use in medical implants, joint replacements and dental applications. Ceramic coatings prevent cytotoxicity and mimic natural bone structures. Their inertness avoids adverse tissue reactions while mechanical properties like high compression strength and toughness provide long-term fixation of implants. Superior tribological performance further enhances device lifetimes.
For instance, in September 2024, Neo Performance Materials, Inc. launched a next-generation zirconia-based ceramic coating with ~15% higher thermal-shock resistance for gas-turbine components.
In terms of process, plasma spray contributes 32.9% of the market share in 2025 owing to its outstanding versatility and ability to spray a wide range of materials. Plasma spraying uses an arc or radio frequency to ionize an inert gas like argon to generate speeds over 10,000°F. This transfers kinetic energy to propel powder particles onto a substrate where they flatten and form a coating. Plasma spraying accommodates most metallic, ceramic, and some plastic powders. It produces dense coatings with low oxide contamination levels for increased corrosion and wear resistance. Plasma spraying can spray nano-sized powders to form coatings with tailored properties. It imparts less thermal stress on components than flame spraying due to its more localized heat source. This minimizes distortion and cracking.
Coatings produced by plasma spraying demonstrate high bonding strength, minimal porosity, and uniform micromorphologies. They deliver longer lifetimes in challenging use cases. The consistent, repeatable character of the plasma spray process also ensures reliable quality between batches and facilities. Overall, plasma spraying stands out versus alternative processes due its unmatched flexibility and ability to manufacture advanced, high-performance coatings.
For instance, in September 2025, Plasmatreat GmbH announced that at “The Battery Show North America 2025” they demonstrated their Openair-Plasma® and PlasmaPlus® technologies to address EV battery module surface challenges (adhesion, corrosion, insulation) using plasma processes.
In terms of application, aerospace contributes 38.1% of the market share in 2025 owing to thermal spray coatings playing a critical role in facilitating operations under extreme environmental conditions within jet engines and aircraft structures. Gas turbine engine components like turbine blades, nozzles, and shrouds experience harsh environments with centrifugal loads, high temperatures up to 3,000°F, and corrosion from combustion gases.
Aerospace structures are also subjected to rain, debris, and bird impacts along with temperature fluctuations between high altitude and ground operations. Thermal sprayed aluminum and anti-corrosion coatings protect aircraft skins and edges and seal fastener joints from environmental degradation. They ensure the long-term integrity of rivets and stringers. As extreme performance and reliability are essential for safety in aerospace, stringent material qualification testing is required.
Thermal spraying suppliers have developed extensive process validation to certify that coatings will perform as designed under simulated engine conditions and survive lifecycles. This technical ability and certification readiness makes thermal spraying mission critical for leading aircraft and jet engine OEMs seeking lowest cost of ownership.
For instance, in June 2024, Oerlikon established a new Advanced Coating Technology Center in Westbury, NY, to service the aerospace and industrial gas turbine industries. The facility integrates thermal-spray and PVD capabilities helping develop “next-generation high-temperature materials and coatings, for aerospace and gas turbine industries
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North America has been the largest and most developed regional market for thermal spray coatings globally with 41.8% of the market share in 2025. The region has a strong presence of major coating manufacturers as well as end-use industries such as aerospace, healthcare, automotive, etc. Moreover, the region has witnessed high industrial research spending over the years to develop advanced thermal spray technologies. Major manufacturing countries like the U.S. and Canada have a robust coating application infrastructure to support thermal spray coating processes for new product development as well as repair and maintenance activities.
For instance, in June 2024, Oerlikon announced the establishment of an Advanced Coating Technology Center in Westbury, New York (USA), integrating thermal spray and PVD capabilities to serve aerospace and gas turbine industries in North America
Asia Pacific region has emerged as the fastest growing market for thermal spray coatings in recent years. The thermal spray coatings market in the region is driven by increasing industrial and manufacturing activities across industries like power generation, oil & gas, electronics, etc. Countries like China, India, Japan, and South Korea are at the forefront of this growth due to rising manufacturing output, foreign investments, and evolving coatings application needs of local industries. The availability of low-cost skilled labor and raw materials in the region allows coatings manufacturers to offer competitive pricing for thermal spray coatings. Additionally, growing exports of finished products from the region have also augmented the demand for coatings application services to maintain high product quality. Overall, strong growth momentum across key end-use sectors coupled with favorable government policies supporting local manufacturing are positioning the Asia Pacific region as the future leader in the global thermal spray coatings market.
The U.S. thermal spray coatings market is expanding in 2025 due to strong demand from aerospace, defense, automotive, and industrial gas turbine sectors. Advanced coating solutions that provide thermal, wear, and corrosion resistance are increasingly adopted to enhance engine efficiency, protect critical components, and reduce maintenance costs. Investments in local R&D centers, facility expansions, and collaborations with OEMs are driving innovation in high-performance ceramic, metallic, and composite coatings. Regulatory pressures and the shift away from traditional coatings are further accelerating the adoption of environmentally friendly and high-durability thermal spray solutions.
For instance, in June 2024, Oerlikon announced the establishment of an Advanced Coating Technology Center in Westbury, New York (USA) to integrate thermal‑spray and PVD capabilities for aerospace and industrial gas turbine industries.
China’s thermal spray coatings market is growing in 2025 due to rising aerospace manufacturing, adoption of lightweight alloys, and expansion in automotive, power generation, and industrial machinery sectors. Local innovation centers and regional service facilities are enabling the development of high-performance coatings tailored to domestic industrial and aerospace applications. Increasing use of corrosion-resistant, wear-resistant, and thermal barrier coatings supports the growth of indigenous aircraft and engine programs.
For instance, in November 2024, BASF Chemetall showcased at Airshow China 2024 a one‑stop aerospace surface‑treatment portfolio, including coatings suited for aircraft structures and engine components, via its local Asia‑Pacific Innovation & Technology Center in Zhejiang Province.
| Report Coverage | Details | ||
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| Base Year: | 2024 | Market Size in 2025: | USD 11.88 Bn |
| Historical Data for: | 2020 To 2024 | Forecast Period: | 2025 To 2032 |
| Forecast Period 2025 to 2032 CAGR: | 6.9% | 2032 Value Projection: | USD 18.96 Bn |
| Geographies covered: |
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| Companies covered: |
Praxair Surface Technologies, H.C. Starck, Bodycote PLC, Oerlikon Metco, Surface Technology International Ltd, ASB Industries Inc., A&A Coatings, Flame Spray Technologies, Metallisation Ltd, TWI Ltd, Metallizing Equipment Co. Pvt. Ltd., Plasma-Tec, Inc., Integrated Global Services, Progressive Surface, FST Coatings Inc., Thermion Inc., Oerlikon Balzers, Tafa Incorporated, Metallizing Equipment Co. Pvt. Ltd., and TST Coatings, Inc |
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Gas turbines are widely used in the power generation, marine propulsion, and oil & gas industries. In power generation, gas turbines play a crucial role in meeting rising electricity demands, especially in developing countries lacking sufficient grid infrastructure. They provide cost-effective, nimble power solutions. Furthermore, industrial gas turbines are gaining popularity in the marine sector to propel large cargo and cruise ships. In offshore oil & gas platforms as well, gas turbines reliably supply power. All key components of gas turbines that endure high stresses and temperatures, such as turbine blades, nozzles, and combustion chambers require special coatings for maximizing performance and lifespan. Thermal barrier and abradable seal coatings are essential in gas turbines. Hence, the continuous growth of the industrial gas turbine industry is propelling the demand for thermal spray materials and services across various applications and components. Many gas turbine OEMs rely on thermal spray coatings to manufacture durable, high-performance products.
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The increasing demand for lightweight and high-performance materials from the aerospace sector can drive growth. In addition, Thermal spray coatings offer corrosion and wear resistance and help increase product lifetime. The growing oil and gas industry and a focus on maintenance, repair and overhaul activities also offer prospects.
The thermal spray coatings market is entering a transformative phase driven by extreme performance requirements and the shift toward high-value, long-lifecycle components in aerospace, energy, and industrial machinery. Regulatory and operational pressures, such as the FAA’s stringent certification standards for jet engine coatings and the Department of Energy’s focus on high-efficiency gas turbines, are accelerating adoption of advanced ceramic and composite coatings. For instance, plasma-sprayed zirconia-yttria thermal barrier coatings now consistently extend turbine blade lifetimes by over 30%, reducing maintenance downtime and operational costs, while coatings like MCrAlY alloys are increasingly used to resist oxidation in gas turbines and aero engines.
Industrial players are strategically integrating in-house thermal spray capabilities with robotic automation and nano-structured powders to tailor coatings for extreme wear, corrosion, and high-temperature resistance. Companies such as Oerlikon and Sulzer are setting benchmarks by combining multi-material, functionally graded coatings with localized testing, enabling customized solutions that outperform traditional hard chrome or HVOF coatings.
End-users, particularly in aerospace and power generation, are showing clear preference for suppliers who provide not only coating performance but also reproducible, certified processes, creating a distinct competitive divide. Firms that fail to invest in precision surface engineering and process validation risk losing contracts, as engine OEMs increasingly demand coatings capable of surviving thousands of thermal cycles without delamination.
*Definition: Thermal spray coatings market provides protective, corrosion, and wear resistant coatings to improve the performance and lifespan of metal components. Thermal spray coatings are applied as a molten or semi-molten material onto a substrate through processes like flame spraying, plasma spraying, or others. Common thermal spray materials include alloys of aluminum, copper, nickel, chromium, and others. They are used across industries like aerospace, automotive, oil & gas, mining, steel, turbines, and others. This market caters to large cosmetic brands as well as small and private label producers worldwide.
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About Author
Vidyesh Swar is a seasoned Consultant with a diverse background in market research and business consulting. With over 6 years of experience, Vidyesh has established a strong reputation for his proficiency in market estimations, supplier landscape analysis, and market share assessments for tailored research solution. Using his deep industry knowledge and analytical skills, he provides valuable insights and strategic recommendations, enabling clients to make informed decisions and navigate complex business landscapes.
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