Coatings are deposited on a substrate by a stream of finely divided particles in a molten or semi-molten state in thermal spray coating processes. Fine powdered material or, in certain cases, the molten metal wire that has been fractured into fine droplets is used in these procedures. The method is most commonly used to apply coatings on a variety of materials and components, providing resistance to wear, erosion, abrasion, heat, cavitation, and corrosion. Thermal spraying can also be used to provide sacrificial wear, electrical conductivity, chemical resistance, friction, lubricity, and a variety of other desired surface characteristics.

Metals, alloys, ceramics, cermets, carbides, polymers, and plastics are some of the coating materials that may be applied with a high deposition rate. Spray coating between two metallurgicallymetal parts is feasible because a thermal spray coating is mechanically attached to a substrate. Spraying is also possible with coating materials that have a greater melting point than the substrate. Thermal spray painting minimizes component deformation and requires little pre-heating or post-heating treatment.

According to Facts and Factors, the global thermal spray coating market was valued at roughly USD 7,600 Million in 2020 and is predicted to create revenue of roughly USD 11,400 Million by the end of 2026, with a CAGR of roughly 7% between 2021 and 2026.

Thermal spray coating is commonly used in engine coating to eliminate the need for highly heavy cast-iron liners, resulting in considerable reductions in fuel consumption, emissions, and corrosion in engine components. The market’s growth is being fueled by the increasing use of X-ray photoelectron spectroscopy and scanning electron microscopy technologies for thermal spray coatings that are sprayed to engines and are extremely successful in preserving engine components such as piston rings and turbochargers. The coating minimizes engine wear and friction, protects against chemicals, and extends the engine’s life cycle. Crankshafts, piston rings, cylinders, and valves are among the many components of fighter jet engines that employ thermal spray coatings. The expanding transportation industry boosts engine demand, which in turn promotes market expansion.

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Top Market Players

Major players operative in the global thermal spray coating market Praxair Surface Technologies, Inc, Lincotek Surface Solutions, BodyCote, American Roller Company, LLC, OerlikonMetco, Powder Alloy Corp., Surface Technology, BryCoat Inc., H.C StarckGmbh, Flame Spray SpA, F.W. Gartner Thermal Spraying, Plasma-Tec, Inc., Arc Spray (Pty) Ltd, John Wood Group PLC, Metallisation Limited, C&M Technologies GmbH, Montreal Carbide Co. Ltd., and AMETEK Inc. amongst others.

Market Dynamics

Because of its oxidation, corrosion, tear, and dimensional reclamation qualities, strong chrome plating has been a viable option for the industry for many years. This coating can be done at low expenses, but it has some limits in terms of component size, thickness build-up, and operational performance. Growing environmental concerns, as well as stricter laws governing the chrome plating process and disposal of its by-products, as well as rising prices, are increasing demand for thermal spray coatings. As a result, it’s become critical for the industry to develop alternative techniques that provide hard chrome plating with equivalent properties but without the associated risks. Thermal spraying technology is gradually emerging as a viable alternative to this technique, with the potential to provide complementary procedures for component safety and reclamation to the chrome plating industry. Chrome plating is significantly less durable than thermal coatings. Furthermore, chrome plating contains micro-cracking inside the layer of plating, allowing corrosive substances with high or low pH to enter the plating and damage the substrate. Micro-cracking may be seen in the photomicrograph below. The fatigue resistance of thermal coatings is far greater than that of chrome plating. High-velocity oxygen fuel (HVOF) coatings apply a compressive force to the substratum, extending component life by preventing fracture start and fatigue failure. Chrome plating produces tensile loads on the surface of the substratum, causing cracks to develop and perhaps premature collapse. The market is expected to increase as end-use industries transition from chrome plating to thermal spraying.

North America is projected to Dominate Global Thermal Spray Coating Market Growth

The region of North America is predicted to dominate the market in the forecasted period owing to the expanding range of applications such as aviation, automotive, engineering coatings, electronics, and energy fields. . During the projected period, the market is anticipated to be driven by the expanding oil and gas industry, notably in North America and the Middle East and Africa. The aviation sector is developing, and demand for the product is progressively increasing. Also, the consumer shift of preference thermal spraying is predicted to be a key market driver in order to fulfill stringent environmental requirements, particularly in North America.

For More Research Insights, Visit, Global Thermal Spray Coating Market, 2021-2026

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