#thermalspray

Thermal Spray Equipment market is expected to grow at a CAGR of 5 % during the forecast period. The Thermal spray equipment market is expected to reach US$ 177.16 Bn. in 2032 from US$ 125.90 Bn. in 2025.

Thermal Spray Equipment market is expected to grow at a CAGR of 5 % during the forecast period. The Thermal spray equipment market is expected to reach US$ 177.16 Bn. in 2032 from US$ 125.90 Bn. in 2025.

Thermal Spray Equipment Market Overview

Stellar Market Research is a Business Consultancy Firm that has published a detailed analysis of the “Thermal Spray Equipment Market”. The report includes key business insights, demand analysis, pricing analysis, and competitive landscape. The report provides the current state of the Thermal Spray Equipment market by thorough analysis, and projections are made up to 2030.

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Thermal Spray Equipment Market Scope and Methodology:

An in-depth study of the Thermal Spray Equipment market is made possible by the report's extensive business facts and analytical insights. Clear presentations of important information are made regarding market size, share, growth patterns, current trends, demand drivers, top competitors, industry profiles, opportunities, value chain analysis, end-user segments, different types, and applications. An accurate estimation of the global and regional Thermal Spray Equipment markets achieved through the use of a bottom-up technique. To create a thorough picture of the Thermal Spray Equipment industry, a strong blend of primary and secondary study techniques is applied. To get knowledge about important actors and examine past and present industry trends, secondary research entailed gathering data from a variety of reliable sources. After that, this data was cross-checked using primary research, which involved speaking with prominent opinion leaders and industry specialists in the Thermal Spray Equipment industry.

The research also examines development prospects in Thermal Spray Equipment markets, giving stakeholders insightful information about possible investments. Included is a thorough competition study that lists the main rivals' product lines. To gain a strategic perspective on the market dynamics, a SWOT analysis is conducted to determine the market's strengths, weaknesses, opportunities, and threats in the Thermal Spray Equipment industry.

Thermal Spray Equipment Market Regional Insights

The Thermal Spray Equipment market's current situation in each of the study's participating countries is shown in the Regional Analysis section. Because the Thermal Spray Equipment industry is so complex, it is imperative to take local opinions into account. The regions that make up the Thermal Spray Equipment market are North America, Europe, Asia-Pacific, Latin America, the Middle East, and Africa. We closely look at the market size, growth rate, imports and exports, and other specific factors of each research region.

Report Url: https://www.stellarmr.com/report/Thermal-Spray-Equipment-Market/916 

Thermal Spray Equipment Market Segmentation:

By Material Ceramics

Ceramics Metals & Alloys

By End-use

Aerospace Automotive Healthcare Agricultural Machinery Energy & Power

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Thermal Spray Equipment Market Key Players:

Praxair Surface Technologies, Inc (U.S.)

BodyCote (U.K.)

Oerlikon Metco (Switzerland)

Surface Technology (U.K.)

H.C Starck Gmbh (Germany)

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

Hoganas AB (Sweden)

Arc Spray (Pty) Ltd (South Africa)

Metallisation Limited (U.K.)

Plasma-Tec, Inc. (U.S.)

C&M Technologies GmbH (Germany)

AMETEK Inc. (U.S.)

Carpenter Technology Corporation (U.S.)

A & A Therman Spray Coatings (U.S.)

Flame Spray SpA (Italy)

BryCoat Inc. (U.S.)

Thermal Spray Technologies, Inc. (U.S.)

Key questions answered in the Thermal Spray Equipment Market are:

Who are the leading companies and what are their portfolios in Thermal Spray Equipment Market?

What segments are covered in the Thermal Spray Equipment Market?

Who are the key players in the Thermal Spray Equipment market?

Which application holds the highest potential in the Thermal Spray Equipment market?

What are the key challenges and opportunities in the Thermal Spray Equipment market?

What is Thermal Spray Equipment ?

What was the Thermal Spray Equipment market size in 2023?

What will be the CAGR at which the Thermal Spray Equipment market will grow?

What is the growth rate of the Thermal Spray Equipment Market?

Which are the factors expected to drive the Thermal Spray Equipment market growth?

What are the different segments of the Thermal Spray Equipment Market?

What growth strategies are the players considering to increase their presence in Thermal Spray Equipment ?

What are the upcoming industry applications and trends for the Thermal Spray Equipment Market?

What are the recent industry trends that can be implemented to generate additional revenue streams for the Thermal Spray Equipment Market?

Key Offerings:

Past Market Size and Competitive Landscape (2018 to 2022)

Past Pricing and price curve by region (2018 to 2022)

Market Size, Share, Size & Forecast by different segment | 2024−2030

Market Dynamics – Growth Drivers, Restraints, Opportunities, and Key Trends by Region

Market Segmentation – A detailed analysis by segment with their sub-segments and Region

Competitive Landscape – Profiles of selected key players by region from a strategic perspective

Competitive landscape – Market Leaders, Market Followers, Regional player

Competitive benchmarking of key players by region

PESTLE Analysis

PORTER’s analysis

Value chain and supply chain analysis

Legal Aspects of Business by Region

Lucrative business opportunities with SWOT analysis

Recommendations

About Stellar Market Research:

Stellar Market Research is a multifaceted market research and consulting company with professionals from several industries. Some of the industries we cover include medical devices, pharmaceutical manufacturers, science and engineering, electronic components, industrial equipment, technology and communication, cars and automobiles, chemical products and substances, general merchandise, beverages, personal care, and automated systems. To mention a few, we provide market-verified industry estimations, technical trend analysis, crucial market research, strategic advice, competition analysis, production and demand analysis, and client impact studies.

Contact Stellar Market Research:

3rd Floor, Navale IT Park, Phase 2

Pune Banglore Highway, Narhe,

Pune, Maharashtra 411041, India

[email protected]

If additional remedial work is needed to get your metal structures and equipment in order, you can count on us to take care of it. Our team are equipped with ultra high pressure water spraying equipment and are trained in abrasive blasting techniques, allowing us to level the surface and remove rust and grime. This will ensure the thermally sprayed aluminium coating achieves the longest lifespan possible.

Heat is one of the most destructive forces in industrial environments. Turbines, engines, reactors, and exhaust systems face extreme temperatures every single day. Without proper protection, metal components crack, corrode, and fail well before their expected service life. That is where thermal barrier coatings step in.

If you work in aerospace, automotive, power generation, or heavy manufacturing, understanding TBC technology could save your operations significant time and money.

What Are Thermal Barrier Coatings?

Thermal barrier coatings, commonly referred to as TBCs, are multilayered ceramic surface coatings applied to metal components that are regularly exposed to intense heat. Think of them as a protective shield that absorbs and deflects heat before it reaches the metal underneath.

A standard TBC system consists of three key layers:

Bond Coat - This is the foundation layer, typically made of NiCrAlY or MCrAlY alloys. It locks the coating to the base metal and provides oxidation resistance.

Thermally Grown Oxide (TGO) Layer - This thin layer forms naturally between the bond coat and topcoat. It plays a critical role in long-term durability and coating stability.

Ceramic Topcoat – Usually yttria-stabilised zirconia (YSZ), this is the primary heat-blocking layer. It has low thermal conductivity and can withstand temperatures up to 1200°C.

Together, these layers reduce metal surface temperatures by up to 250°C. That kind of temperature drop significantly reduces stress on the component, reduces oxidation, and maintains consistent performance over longer periods.

Where Are Thermal Barrier Coatings Used?

TBCs are not limited to one industry. Their applications are wide and growing:

Aerospace and Power Generation - Turbine blades, vanes, combustors, and hot-gas-path components rely heavily on heat-insulating coatings to operate safely at extreme temperatures.

Automotive - Turbochargers, pistons, headers, and exhaust systems benefit from protective ceramic coatings that manage heat buildup and improve engine efficiency.

Process and Chemical Industries – Reactors and high-enthalpy equipment operating in harsh chemical environments use TBCs for both heat resistance and corrosion protection.

If heat is directly impacting your component's performance or lifespan, thermal barrier coating is likely the most practical surface engineering solution available.

Key Benefits You Should Know

Extended Component Life - By reducing the thermal load on metal surfaces, TBCs dramatically slow down wear and degradation. Parts last longer, and replacement cycles become less frequent.

Lower Maintenance Costs - Fewer breakdowns mean fewer shutdowns. Industries that adopt heat-resistant coatings report measurable reductions in maintenance expenditure over time.

Resistance to Oxidation and Corrosion – Specialised bond coats provide long-term resistance to both atmospheric and chemical attack, which is critical in aggressive operating environments.

Thermal Shock Resistance – Good TBC systems are built to handle repeated heating and cooling cycles without spalling or cracking. This is especially important in gas turbines and automotive engines.

Compliance with Performance Standards – Quality TBC applications are measured, tested, and qualified against ISO and ASTM standards, giving engineers reliable, documented results.

Choosing the Right TBC Material

Not all thermal barrier coatings are the same. The right material depends on your operating temperature, environment, and performance requirements.

Yttria-Stabilised Zirconia (YSZ) remains the most widely used option. It offers excellent thermal shock resistance and stability up to 1200°C, making it ideal for gas turbines and aerospace components.

Mullite works well in lower-temperature applications below 800°C. It offers good mechanical strength and corrosion resistance at a lower density.

Alumina (Al₂O₃) is often added to YSZ blends to boost oxidation resistance in demanding environments.

Ceria and YSZ Blends are used where enhanced thermal cycling performance is required, providing components with better insulation and shock tolerance.

Selecting the right formulation is not guesswork. It requires an experienced surface engineering team that understands both material science and real-world operating conditions.

Ready to Protect Your Components from Extreme Heat?

If your industrial parts are failing early, running hot, or costing too much to maintain, it is time to explore thermal barrier coating as a long-term fix. Plasma Spray Processors has over 40 years of hands-on expertise in surface coating and component life enhancement, serving industries across India from steel and aerospace to automotive and power. Whether you need to coat new parts or recoat worn components, their team offers customised TBC solutions with fast turnaround times, ISO-qualified processes, and no minimum order requirements.

Get in touch with Plasma Spray Processors today to find the right heat-protection solution for your application.

Frequently Asked Questions

What does a thermal barrier coating actually do? It insulates metal surfaces from extreme heat, reducing thermal stress and extending the working life of critical components.

Can TBCs be applied to parts that are already in use? Yes. Used components can be inspected, cleaned, and recoated after proper surface preparation, making them a cost-effective alternative to buying new parts.

What temperature range can thermal barrier coatings handle? High-quality TBC systems can withstand operating temperatures up to 1200°C, depending on the material formulation and application.

How long does the coating process take? The standard turnaround is 5 to 7 working days. Emergency or breakdown jobs can be handled within 24 to 48 hours.

The soaring demand for next-generation aircraft has placed Thermal Spray Coating Equipment at the forefront of aerospace innovation this year. The Thermal Spray Coating Equipment market was valued at USD 12.8 Billion in 2023 and is projected to grow to USD 19.5 Billion by 2030, with a compound annual growth rate (CAGR) of 6.5% from 2024 to 2030. As 2026 manufacturers strive for higher engine temperatures to achieve better fuel efficiency, the role of plasma and HVOF spray systems becomes critical. These machines apply ultra-thin, high-durability ceramic barriers that allow turbine blades to operate well above the melting point of their base alloys. This thermal management is essential not only for commercial aviation but also for the burgeoning private space sector, where re-entry vehicles require robust heat shielding to survive atmospheric friction.

According to the latest Thermal Spray Coating Equipment Market Report, the push for sustainable aviation is driving a shift toward electric energy-based spray processes. In 2026, the industry is moving away from traditional combustion methods to minimize the carbon footprint of the manufacturing process itself. These advanced electrical systems provide superior control over particle velocity and temperature, resulting in coatings with near-zero porosity and exceptional bond strength. By reducing weight through thinner yet more effective layers, aerospace engineers are hitting their 2030 sustainability targets while simultaneously extending the service life of critical engine components.

The global thermal spray market is experiencing significant momentum, driven by growing demand across key industries such as aerospace, automotive, healthcare, and energy. As we look ahead to 2032, the market is projected to expand at a steady pace, with advancements in material science, surface engineering, and coating technologies acting as primary catalysts.

Thermal spray technology involves the application of coatings using heat to melt materials and spray them onto surfaces to improve wear resistance, reduce corrosion, and enhance thermal insulation. This process is widely used to extend the life of critical components, especially in extreme operational environments. With the continued industrial push for efficiency and longevity of machinery, the importance of high-performance coatings has surged.

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Market Size and Share Outlook

The thermal spray market size was valued at USD 11.77 billion in 2024 to USD 17.52 billion by 2032, growing at a CAGR of 5.1% during the forecast period (2025-2032). North America remains a dominant player, with a strong aerospace and defense sector, followed closely by Europe and the Asia-Pacific region. Emerging economies are rapidly adopting thermal spray technologies, particularly in energy, infrastructure, and transportation applications.

Within the market, thermal spray coatings hold the largest share, with plasma spray and high-velocity oxy-fuel (HVOF) techniques being the most prevalent. Among materials, ceramics and metal-based coatings are projected to maintain dominance due to their high resistance to wear and corrosion. Equipment and services are also witnessing increased demand, as more industries shift from conventional coating methods to thermal spray processes.

Thermal Spray Market Segments Analysis

Global Thermal Spray Market is segmented by Material, Technology, Application and region.

Based on Material, the market is segmented into Metals, Ceramics, Intermetallic, Polymers, Carbides, Abradable and Others.

Based on Technology, the market is segmented into Cold Spray, Flame Spray, Plasma Spray, HVOF, Electric Arc Spray and Others.

Based on Application, the market is segmented into Aerospace, Industrial Gas Turbine, Automotive, Medical, Printing, Oil & Gas, Steel, Pulp & Paper and Others.

Based on region, the market is segmented into North America, Europe, Asia Pacific, Latin America and Middle East & Africa.

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Key Drivers of Growth

Several factors are contributing to the sustained growth of the thermal spray market:

1. Expansion of Aerospace and Defense Applications: Components in jet engines, turbines, and landing gear require high-performance coatings that withstand extreme temperatures and pressures, making thermal spray indispensable in these applications.

2. Rise in Automotive and Industrial Manufacturing: Lightweight materials and high-efficiency engines are becoming standard in automotive design. Thermal spray enhances engine performance and longevity, supporting regulatory goals for emissions and fuel efficiency.

3. Advances in Medical Devices and Implants: Thermal spray coatings are increasingly used in orthopedic and dental implants to improve biocompatibility and implant durability, reflecting growth in the healthcare sector.

4. Renewable Energy and Power Generation: As the global energy landscape shifts, thermal spray is playing a vital role in protecting equipment in wind, hydro, and thermal power plants from wear and corrosion, especially in harsh environmental conditions.

5. Technological Innovations: Ongoing developments in spray equipment, robotics, and digital control systems are improving process consistency and reducing operational costs, making thermal spray more accessible to a broader range of industries.

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Top Players in Thermal Spray Market

OC Oerlikon Management AG (Switzerland)

Kennametal Inc. (USA)

Chromalloy Gas Turbine LLC (USA)

Bodycote plc (UK)

Linde plc (Ireland)

Saint-Gobain S.A. (France)

Sandvik AB (Sweden)

Curtiss-Wright Corporation (USA)

Castolin Eutectic GmbH (Germany)

Höganäs AB (Sweden)

H.C. Starck Inc. (USA)

Flame-Spray Industries, Inc. (USA)

Praxair Surface Technologies, Inc. (USA)

Carpenter Technology Corporation (USA)

Fujimi Incorporated (Japan)

Durum Verschleiss-Schutz GmbH (Germany)

Montreal Carbide Co. Ltd (Canada)

GTV Verschleißschutz GmbH (Germany)

Genie Products, Inc. (USA)

Imperial Systems, Inc. (USA)

Challenges and Restraints

Despite its strong growth trajectory, the market faces some constraints. High initial investment costs for thermal spray equipment and skilled labor shortages can be barriers to adoption, particularly for small and mid-sized enterprises. Moreover, environmental regulations related to particulate emissions and materials handling continue to challenge manufacturers, pushing them toward more sustainable solutions.

Future Outlook

Looking forward to 2032, the thermal spray market is poised for innovation-driven growth. The integration of automation, AI, and data analytics into spray systems is likely to enhance process efficiency and quality control. Additionally, the focus on sustainability will encourage the development of eco-friendly coating materials and cleaner application methods.

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Thermal Spray process is ideal for laying extremely thin, dense and hard protective coatings. In comparison, Arc welding process is ineffective and economical on account of the possibility of distortion and removal of large quantity of metal during machining even when a thin overlay is required. 

Even a gas welding process causes unwanted distortions and delays.This makes a Thermal spray process the preferred solution for this kind of applications. In thermal spray method, there are four types of processes.

1. Thermospray Combustion Powder Spray systems 2. Electric Arc wire spray process 3. High velocity Oxy-Fuel Process 4. High Energy Plasma Process.

Thermospray Combustion powder (Spray& fuse grade powders) systems

This technique applies to the arranging of coating materials, including self-fluxing alloys,fine ceramics, self-bonding materials and other special alloys. This process uses fuel gas and Oxygen to achieve the coating using specialized thermal spray equipment.

Key Benefits:  Resists wear & can help salvage worn out components  Resists high temperatures and enhances electrical properties  Cost reduction with better performance

Electric Arc wire spray process

We can coat a range of metallic alloys & pure metal for the restoration of corrosion wear. This process uses Twin arc electric arc spray system, with compressed Air.

Key benefits:  Very simple & easy to maintain  High spray rates with low gas consumption  Coating intricate shapes & improving machinability

High velocity Oxy-Fuel Process

This process uses High velocity Oxy-fuel systems to achieve excellent bonding. In this process, we get dense coating with homogenous structures.

Key Benefits:

 Thin & thick coating possible –even hard carbide and super alloy coating can be given  Process can be fully automated with a robot  Excellent for multiple wear factors

High Energy Plasma Process

This uses high energy plasma spray systems to coat material, this process we can coat metals, alloys, ceramics, cements, carbides & other non-metals.

Key benefits:  Coating possible using different layered material  High deposition rates and excellent bonding  Coating for internal geometry and process can be automated.