Thermal sprays are widely used in the medical devices, oil and gas, aerospace, automotive, electronics, energy and power, rubber, mining, industrial manufacturing, textile, and food processing industries. According to P&S Intelligence, the aerospace industry used the highest quantity of thermal spray materials in the past, especially in the coatings applied on turbo-machinery, such as rotor-path linings, engine components, compressor seals, high-pressure turbine seals, airframes, and oil seals. The aerospace industry uses these materials to improve fuel efficiency, enhance fluid dynamics, reduce maintenance costs, and decrease wear and tear.

In recent years, the usage of thermal spray materials has significantly surged in the Eastern European and Asia-Pacific (APAC) regions due to the vast population and rapid urbanization here. These two factors have, in turn, led to a massive demand for machinery in the consumer products, construction, and automotive industries. Such equipment requires thermal spray coatings to protect them from wear, erosion, corrosion, and any other type of damage, which is why chemical companies that provide these materials are witnessing consistent business growth.

The categories under the type segment of the thermal spray materials market are powder, ceramic-based, wire/rod, and polymer and other material-based. In 2018, the wire/rod category accounted for the largest market share because the usage of wires/rods only propels molten droplets toward the substrate, which helps in minimizing wastage. Moreover, the flame coming out of the spraying machine nozzle is concentric with the wire/rod, which guarantees consistent heating for efficient spraying of the materials.

Over the years, kinetic spraying or cold gas spraying has emerged as one of the most-efficient spray technologies across the world. In this novel process, solid particles are shot on the substrate at high velocities to form coatings on the surface. This process is compatible with nanocrystalline materials and metals and alloys of titanium. Moreover, the advent of advanced technologies, such as non-destructive testing (NDT), and the low cost of the kinetic spraying process will encourage its adoption in the foreseeable future.

Geographically, the North American region held the largest share in the thermal spray materials market in 2018. This can be attributed to the presence of major military and civil aircraft manufacturing companies in the region, such as Bombardier Inc., The Boeing Company, and Lockheed Martin Corporation. Moreover, the existence of leading automotive companies, such as Ford Motor Company, General Motors (GM), Tesla Inc., Chevrolet, Lincoln, Chrysler, and Jeep, also stimulates the market growth in the region.

Thus, the growing aerospace industry, on account of the high demand for commercial and military aircraft and high penetration of aerial transportation, will result in the high-volume consumption of thermal spray materials in the coming years.

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