Thermal spray Market Trends

Introduction

Towards 2024, the market for thermal spray is going to be transformed, pushed by a confluence of macroeconomic factors, such as the speed of technological development, the rise in the regulatory pressure and the change in the customer's habits. The evolution of the processes of application of the thermal spray is going to make the performances of the coatings increase and the number of applications multiply, especially in the aeronautical, the automobile and the energetic sectors. Moreover, the enlargement of the regulations on the environment is going to lead the manufacturers to adopt a more sustainable policy, which will influence the choice of the materials and the process. Also, the change in the habits of the consumers, resulting from the growing importance of the resistance and the efficiency of the products, will push the companies to invest in the advanced solutions of the thermal spray. These tendencies are strategic for the operators, since they not only determine the future competition, but also the direction of the investments and the innovations of the market.

Top Trends

1. Increased Adoption of Advanced Coating Technologies
   A shift is occurring in the thermal spray market towards advanced coating techniques, such as high-velocity oxygen-fuel and cold spray. The industry’s leading companies are investing in R&D to improve coating performance, and companies like Oerlikon Metco are launching new products. The trend is being driven by the demand for better wear and corrosion protection in the aero- and automobile industries. The expected improvements in performance should result in lower maintenance costs.
2. Sustainability and Eco-Friendly Practices
   The development of sustainable production in the thermal spray industry is a major trend. For example, General Magnaplate is currently exploring non-toxic coatings as a means of complying with statutory requirements. This trend is supported by government initiatives to promote the use of green technology, which are also influencing the way the industry operates. It is expected that the move towards sustainable production will enhance the company’s reputation and attract the interest of eco-conscious clients.
3. Integration of Industry 4.0 Technologies
   It is the integration of the IoT and the AI of Industry 4.0 that is transforming the industry. Praxair's surface treatment business, for example, uses data analysis to optimize the process and ensure quality control. It is expected that this trend will increase productivity and reduce waste, as the real-time monitoring allows the system to be adjusted in real time. Further developments may see fully automatic thermal spraying systems, which will further improve the process.
4. Growing Demand in Aerospace and Defense Sectors
   The spheres of aviation and defence are responsible for a great demand for sprayed coatings, due to their need for high-performance materials. The major suppliers of the industry have responded by developing special coatings that meet the strict requirements of the aeronautical industry. The United States government, for example, is investing in advanced materials for military use, which is expected to boost the market. The trend is likely to result in greater cooperation between the manufacturers and the suppliers of military products.
5. Expansion of Applications in Medical Devices
   The medical industry, especially in the field of surgical instruments and implants, is increasingly using the advantages of the thermal spray method. Among the companies that have been specializing in the field for many years are companies like A & A Thermal Spray Coatings, which develops biocompatible coatings for enhancing the performance of medical devices. This trend is backed by regulatory authorities that are putting an ever-greater emphasis on the importance of material safety in the field of medicine. The medical field will probably open up new markets for the thermal spray industry.
6. Focus on Customized Coating Solutions
   A growing trend is towards the provision of tailored thermal spray solutions for specific industry needs. Companies are investing in bespoke coatings that can enhance the performance of products. For example, SINTEF is able to provide tailor-made coatings for individual customer requirements. This is expected to increase customer satisfaction and loyalty as companies seek to differentiate themselves in the marketplace.
7. Emergence of Nanostructured Coatings
   Nanostructured coatings are gaining in importance on the market of the spraying industry because of their improved properties such as increased hardness and wear resistance. Institutions and companies are collaborating to develop these advanced materials, with promising results in a variety of applications. It is expected that the use of these coatings will lead to a revolution in the automotive and aeronautical industries. In the near future, the use of these new coatings will be extended.
8. Increased Investment in Automation
   There has been a noticeable increase in the use of automation systems in the field of thermal spraying in order to increase production efficiency. It has been found that companies are turning to automation to reduce their operating costs and to increase the quality of their coatings. For example, Plasma-Tec Inc. has been implementing automation systems in order to improve the quality of their operations. This trend is expected to lead to higher production rates and reduced operating risks, thereby increasing the competitiveness of these companies.
9. Regulatory Compliance and Quality Standards
   In the market for sprayed coatings, regulatory compliance is becoming more and more important. To ensure the quality of the products, companies must follow the guidelines of the organizations such as ASTM and ISO. The trend of the time is to have a process of quality assurance, which is costly and which can be a source of concern for the manufacturer. However, compliance can enhance market credibility and open up new business opportunities.
10. Rising Demand for Thermal Barrier Coatings
    Demand for TBCs is growing, especially in high-temperature applications like gas-turbines. The leading TBC companies are now concentrating on developing TBCs with improved thermal resistance and life-span. The aeronautical industry, backed by government contracts, is a major driver of this trend. As TBC technology develops, it will lead to more efficient energy use and reduced emissions in a variety of applications.

Conclusion: Navigating the Thermal Spray Landscape

The market for thermal spraying will be characterized by high competition and significant fragmentation in 2024. The market is highly fragmented and has many established and new players. Competition is very intense, and the strategies of the market participants will have to be adapted accordingly. The established companies rely on established relationships and experience, and the newcomers on innovation and specialization. The success of the market will be determined by the implementation of key capabilities, such as the integration of artificial intelligence, automation, sustainable practices and operational flexibility. The suppliers must focus on these key capabilities to improve their competitiveness and meet the changing customer requirements in the dynamic environment.