Thermal Spray Coating For Oil And Gas Market Report 2025 (Global Edition)

Global Thermal Spray Coating For Oil And Gas Market Report 2025 Market Size Split by Type (Arc Spraying, Cold Spray, Flame Spray, Plasma Spray, Detonation Spraying, High-Velocity Oxy-Fuel Spraying, Ot...

Thermal Spray Coating For Oil And Gas Market Report Description

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Top Companies in Thermal Spray Coating For Oil And Gas Market

Chemical and materials companies are facing some challenges including stringent rules & regulation, supply chain disruption along with raw material price volatility. Thus, some of the key players are adopting new technologies to enhance their product portfolio. Now days digital technologies play an important role in this sector because it improves efficiency, operations and productivity of the plant. This study helps you to understand the competitor’s revenue generation, key strategies, recent development coupled with its S.W.O.T analysis.

 

Top Companies Market Share in Thermal Spray Coating For Oil And Gas Industry: (In no particular order of Rank)

• Praxair Surface Technologies Inc.
• Metallization Ltd.
• Flame Spray Coating Co.
• Precision Coatings Inc.
• Montreal Carbide Co. Ltd.
• Kennametal Inc.
• Oerlikon Metco
• Höganäs AB
• Wall Colmonoy Corporation
• Fujimi Incorporated
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*List of Second Tier Companies, List of Third Tier/ Start-up Companies (Inquire with sales executive) Request Any Company Profile for Preview Purpose OR Data Validation!

If any Company(ies) of your interest has/have not been disclosed in the above list then please let us know the same so that we will check the data availability in our database and provide you the confirmation or include it in the final deliverables.

The biggest player in the global oil and gas thermal spray coatings market, Asia-Pacific is expected to grow at a rate of XX% during the forecast period. The main cause of the high growth of the market is the increasing demand for thermal spray coatings in the oil and gas, automotive, aerospace, and energy and power industries in key economies such as China, Japan, and India. The thermal spray coatings market of the region could grow due to the huge demand for automobile components that have to withstand extremely high temperatures and pressures. Furthermore, China is the biggest producer and consumer of thermal spray coatings in Asia-Pacific. Moreover, increasing demand for energy, power, chemicals, is fueling a huge growth of the Indian market. In India, the government's efforts to enhance domestic oil and gas production have resulted in more infrastructure development, which in turn has fuelled the demand for thermal spray coatings. The Ministry of Petroleum and Natural Gas has played a key role in fostering policies that attract investment in exploration and production, indirectly fueling the development of thermal spray coating. 
https://www.etvbharat.com/en/!bharat/india-boosts-domestic-oil-and-gas-production-to- 
In India, business entities such as ONGC (Oil and Natural Gas Corporation) depend on thermal spray coatings to shield equipment utilized in offshore exploration and drilling against corrosion caused by seawater.
https://environmentclearance.nic.in/writereaddata/Online/EDS/0_0_13_Sep_2019_1001081931B80CompressedEIA.pdf 

Demand from crucial industries for oil and gas drives the North American market for thermal spray coatings for oil and gas. The harsh weather conditions, exposure to saltwater, and operational difficulties in offshore platforms necessitate corrosion resistance. Thermal spray coatings, including zinc-aluminium alloys and chrome oxide coatings, are widely applied to prevent corrosion. The ease of access to raw materials in the region helps to fuel the growth of the global market for thermal spray coatings. The US, specifically, has its infrastructure strong, needing constant care and protection in which thermal spray coatings are very widely applied. The US and Canadian governments also support projects aiming to create highly developed coatings as well as promote standards for thermal spray coatings that can stimulate growth in the market. In February 2022, to give another illustration, the government of Canada has declared that it will utilize $24 million under the New Frontiers in Research Fund to build novel molecular coatings that have the potential to reduce maintenance expenses in many industries. 
https://www.carbon-2-metal-institute.queensu.ca/post/funding-celebration-for-carbon-to-metal 

The demand for thermal spray coatings in the oil and gas industry in Europe will grow due to the expanding R&D spending of the pharmaceutical industry. The sector is anticipated to develop rapidly due to Russia's strong demand for natural gas and crude oil and manufacturers' increasing application of enhanced oil recovery. 
https://www.opec.org/opec_web/en/882.htm

Europe plays a major role in the demand for thermal spray coatings. These nations such as the United Kingdom, Norway, and Germany possess significant offshore and onshore oil and gas facilities where equipment longevity is paramount. The European region has experienced continued uptake of thermal spray technologies for minimizing maintenance expense and maximizing equipment performance. Europe is aiming to improve energy efficiency and minimize carbon emissions, which is why there is demand for materials with high temperature endurance and low energy loss in drilling equipment and pipelines. Environmental protection and operational safety regulations by the government have further promoted the use of advanced coatings. For example, the European Union's industrial emissions and equipment safety standards require the application of high-performance coatings to meet strict guidelines.  
https://www.cbi.eu/market-information/apparel/buyer-requirements 

Africa and the Middle East are the largest oil producers globally. The region has strong product demand in the oil and gas sector because it hosts key oil-producing nations like Saudi Arabia, Kuwait, Oman, Bahrain, Libya, Iraq, Angola, and Iran. The Middle East comprises five of the leading ten oil-producing nations and is credited with producing approximately 26% of global output.
Saudi Arabia is the globe's leading oil producer and is responsible for producing approximately 15% of world output. 
https://www.investopedia.com/articles/investing/101515/biggest-oil-producers-middle-east.asp 
The hot and dry climate of the region requires coatings that offer increased wear and corrosion protection. Coatings like tungsten carbide and chrome-containing materials are frequently employed. Although the coatings are required for protection, the harsh environmental conditions of the area demand continuous innovation in coating technology to maintain long-term performance. The oil and gas sector in Africa is growing, especially in Nigeria, Angola, and South Africa. Thermal spray coatings are increasingly being used as the production of oil and gas in the region increases. 

Latin America, particularly nations such as Brazil, Venezuela, and Argentina, boasts a developing oil and gas sector. Expansion of the infrastructure and exploration processes in the region support the rise in demand for thermal spray coatings. With an emphasis on boosting oil and gas production by nations in Latin America, the requirement for coatings to resist wear, corrosion, and temperature ranges becomes essential. The economic climate in Latin America often results in demand for cost-effective solutions that are value for money and that reduce maintenance expenses. Brazil, for instance, has heavily invested in offshore oil exploration, generating high demand for coatings to fight the aggressive marine environment. 
For example, in Brazil, Petrobras, the government-owned oil giant, has used thermal spray coatings on offshore oil rigs and subsea equipment to withstand the corrosive action of seawater and enhance the lifespan of vital components.
https://www.britannica.com/money/Petrobras 




 

The current report Scope analyzes Thermal Spray Coating For Oil And Gas Market on 5 major region Split (In case you wish to acquire a specific region edition (more granular data) or any country Edition data then please write us on info@cognitivemarketresearch.com

• North America (United States, Canada, Mexico)
• Europe (United Kingdom, France, Germany, Italy, Russia, Spain, Sweden, Denmark, Switzerland, Luxembourg, Rest of Europe)
• Asia Pacific (China, Japan, South Korea, India, Australia, Singapore, Taiwan, South East Asia, Rest of APAC)
• Latin America (Brazil, Argentina, Colombia, Peru, Chile, Rest of South America)
• Middle East (Saudi Arabia, Turkey, UAE, Egypt, Qatar, Rest of Middle East)
• Africa (Nigeria, South Africa, Rest of Africa)

The above graph is for illustrative purposes only.

Thermal Spray Coating For Oil And Gas Market Analysis

Based on type Arc spraying segment dominates XX% of market share in 2024. The most economic thermal spray technique for depositing corrosion-resistant metal coatings, for example, of zinc, aluminium, and alloys thereof, is typically arc spraying. With respect to other processes such as flame spraying, there are reduced energy costs and improved production rates. Due to extensive application on broad surfaces and material types, the plasma spray technology is anticipated to develop enormously in the forecast period.
Two expendable metal wires are introduced to a spray gun in this process, where they are energized to create an electric arc between them. As the wire is passed through, the arc's heat melts the wire, and an air jet shot from the gun then captures the molten material. The melted feedstock is injected onto a substrate by the high-pressure air jet, generally creating a thick metallic coating. In its application in the oil and gas sector, arc spraying is used to shield vital equipment from corrosion, particularly in aggressive environments such as offshore oil rigs, pipelines, and refineries. The capacity to quickly and economically coat large surfaces is essential in such industries where there is a need for protection from saltwater corrosion, abrasion, and wear.
Arc spraying is employed to deposit zinc-aluminium coatings on pipelines to protect them from rust and corrosion caused by exposure to corrosive materials and extreme weather conditions. The application serves to prolong the life of the infrastructure, saving on expensive replacements or repairs. For instance, it highlights that arc spraying offers superior protection against marine environments, where saltwater can quickly corrode metal structures.
https://www.haydencorp.com/arc-spray-what-is-it-and-how-does-it- .
 

Employing a high-pressure carrier gas to accelerate fine powder particles to supersonic velocities, cold spraying is an advanced solid-state material deposition process that deposits the particles onto a substrate. The particles undergo extreme plastic deformation upon impact and bond to the substrate without melting, resulting in dense deposits that can be utilized in near-net-shape additive manufacturing, coatings, and repair. Like explosion welding, the bonding process ensures high adhesion and minimal heat effect on the substrate, preserving the material's properties and avoiding issues such as thermal distortion or oxidation. For example, cold spraying in the oil and gas sector applied in the repair of equipment like gas turbines, pipelines, and offshore platforms. Cold spray technology has been applied to deposit corrosion-resistant coatings to these components and enable them to resist extreme environment conditions, which include exposure to chemicals, hot temperatures, and humidity. Cold spray coatings extend the life of components considerably but preserve their mechanical properties. The technology is suited for coating pipes and other main components that get exposed to aggressive environments. The cold spray process shows an improvement in corrosion resistance and allows for repairs to parts with little need for extensive heat treatment.
https://www.mdpi.com/2079-6412/14/7/822 

The largest market share was that of the flame spray sector. Thermal spray coating is applied with the flame spraying technique utilizing an oxy-acetylene flame. Compressed air drives the coating material to the sprayed product while the flame's heat melts it. Preventing corrosion, high-quality metal coatings can be applied through the flame spray. This process generates heat in a consumable wire or powder through the combustion of an oxygen mixture with a fuel gas (propane, hydrogen, acetylene, propylene, or propane). The heated consumable is directed at a substrate utilizing compressed air or inert gas. Although being less costly and delivering a modest spray rate, flame-sprayed coatings are found to be very porous, to have a high oxide level, and poor bonding strength. 
For instance, a major oil and gas firm showed the successful implementation of flame spray coatings to subsea pipeline equipment, decreasing corrosion rates and increasing the lifetime of these important assets
https://www.researchgate.net/publication/375489336_Advances_in_corrosion_protection_coatings_A_comprehensive_review 
In the oil and gas industry, flame spraying is commonly utilized to deposit corrosion-resistant coatings on equipment and machinery exposed to corrosive environments like pipelines, pumps, and valves. One of the key advantages of flame spraying is that it can form coatings that shield components against corrosion due to exposure to severe chemicals and seawater. 

Medical dental implants may be manufactured with the help of HVOF technology. During the forecast period, growth in demand would be aided by this industry's growth. The process can even be utilized to refurbish the size of a worn part or section that has been incorrectly machined since it is easy to keep track of the thickness of the coating.
HVOF coatings are especially valuable for parts experiencing severe wear environments, including components in drilling systems or parts exposed to extreme temperatures and pressures. HVOF coatings have excellent bond strength to improve substrate adhesion, eliminating coating failure as a major factor. The coat's consistency is also helpful in reviving worn-out parts such that important parts of a mechanism are maintained within functional capabilities. For instance, in offshore drilling processes, HVOF has been utilized for the coating of drill bits and abrasive wear components with considerable extended lifetimes. 
https://www.inscience.in/JTSE/409%20Pradeep%20et%20al.pdf 
This method employs the burning of propane as a jet of compressed air. This generates a high velocity, smooth jet into which the coating particles are injected in such a manner that they are forced at the substrate. This can provide smooth, ductile coatings with an acceptable mechanical bond strength (over 12,000 psi).

A DC electric arc is employed to produce a hot plasma gas to heat a powder consumable when it is injected into the plasma jet. Inert gas is supplied to the torch, which expands to produce a high-speed jet that has the capability of accelerating particles with velocities of the order of 200-300 m/s. This technique produces superior coatings from high melting point materials. The application of a vacuum in vacuum plasma spraying (VPS) or low-pressure plasma spraying (LPPS) will provide even better-quality coatings, but at a greater expense.
For instance, plasma spraying is used frequently on components for offshore platform gas turbines that experience high temperature and corrosive gases. Gas and steam turbines utilize plasma spray coatings to increase efficiency and protect against thermal fatigue.
https://shop.machinemfg.com/plasma-spray-coating-process-and-applications/#
This method is commonly applied in the coating of turbine parts, seals, and other high-temperature components. Plasma spraying may also be performed in a vacuum (Vacuum Plasma Spraying, VPS) or low-pressure atmosphere (Low Pressure Plasma Spraying, LPPS), giving even more superior-quality coatings. Advantages of plasma spraying are highly durable wear resistance, oxidation resistance, and being capable of forming coatings with extremely particular characteristics.
 

The above Chart is for representative purposes and does not depict actual sale statistics. Access/Request the quantitative data to understand the trends and dominating segment of Thermal Spray Coating For Oil And Gas Industry. Request a Free Sample PDF!

Application Segment Analysis of Thermal Spray Coating For Oil And Gas Market

Chemical and materials are one of the most important industries for other sectors including automotive, pharmaceutical, personal care, consumer goods and others. The demand for high quality and environment friendly products is increasing in various end-use sectors. Thus, key manufacturers are focusing on technological advancement in production of high-quality chemicals. The segment analysis will help to understand which is the most attractive application/end use sector. It also provides the year on year (Y-O-Y) growth rate for each segment. Moreover, this study includes the detailed analysis of each segment to understand the key positive and negative factors which are impacting the growth of the Thermal Spray Coating For Oil And Gas Market.

Some of the key Application of Thermal Spray Coating For Oil And Gas are:

• Automotive
• Industrial
• Aerospace
• Others

The above Graph is for representation purposes only. This chart does not depict actual Market share.

Thermal Spray Coating For Oil And Gas Materials Segment Analysis

Based on material ceramic segment dominates XX% of Market share in 2024. Ceramic coatings are widely used in the oil and gas industry due to their corrosion resistance and thermal stability. The ceramics market accounts for the largest share based on material. Ceramic coatings are light compared to more traditional protective materials such as metal alloys. Ceramic coatings may be applied to components to enhance performance without notably adding to their weight. Consequently, it is expected that all of these drivers will enhance the thermal spray coatings market through their increased application in anode manufacturing. The metal, ceramics, intermetallic, polymers, carbides, abradable, and others are the segments of the market. The ceramics segment is expected to have the largest market share of xx% by 2030. Due to its cost-effectiveness and accessibility, ceramic material is in high demand. Metals and alloys are the most widely consumed materials, followed by ceramics. Metals and alloys are expected to be the second-highest consumed material in the market throughout the forecast period. Gas turbines are widely utilized for power generation and mechanical drive in the oil and gas sectors. These turbines work in conditions that subject them to very high temperatures, high pressures, and corrosive chemicals. To provide longevity to turbine blades and other vital parts, ceramic thermal spray coatings are deposited.
For instance, ceramic coatings, like yttria-stabilized zirconia (YSZ), are typically applied to offer thermal insulation, oxidation resistance, and enhanced efficiency of the turbines. The coatings are deposited on turbine blades through a high-temperature method that enables the ceramic material to adhere to the substrate without compromising the integrity of the base material. Journal of Thermal Spray Technology, 2022, features the application of zirconia-based ceramic coatings for gas turbines in the oil and gas industry. The coating is highly effective in thermal insulation and corrosion resistance, which serves to prolong the operational life of turbine parts in harsh environments.
https://link.springer.com/article/10.1007/s11666-020-01047-0 

Carbide coatings are used on parts to impart abrasion, adhesion, eroding, and fretting resistance. Their elevated melting point and ability to maintain strength, hardness, and wear resistance at high temperatures make them ideal for coating wear plates, fixtures, pump housings, and gate valves. Carbide-based thermal spray coatings are also used to coat high-value parts, which is expected to increase their market demand. In the oil and gas sector, these coatings are used to safeguard costly parts like wear plates, valves, pump casings, and turbine parts from the extreme wear and corrosion caused by extreme working conditions. Out of the numerous varieties of coatings that are employed, carbide thermal spray coatings including tungsten carbide and chromium carbide find immense demand since they possess far greater hardness and wear resistance while also being more capable of surviving high temperatures.
The main benefit of the application of carbide coatings in the oil and gas industry is that they have the ability to improve wear and corrosion resistance. They are most often applied by thermal spray processes, such as plasma spraying or high-velocity oxy-fuel (HVOF) spraying, in which metal powders (e.g., chromium carbide or tungsten carbide) are melted and subsequently sprayed onto the substrate. When cooled, these particles adhere to the surface and form a tight, protective layer that is resistant to erosion, fretting, and abrasive wear. 
For instance, a major oil and gas producer employed high-velocity oxy-fuel (HVOF) spraying to deposit tungsten carbide coatings on pump housings subject to abrasive slurries and high-pressure flow in subsea pipelines. This coating extended the lifespan of the parts by a great degree, as it offered greater protection against erosion and corrosion, decreasing maintenance and replacement frequency.
https://htscoatings.com/pages/hvof-spray 
 

• Ceramics and Metals
• Intermetallic
• Carbides
• Abradable
• Polymer Coatings

Thermal Spray Coating For Oil And Gas Process Segment Analysis

Based on process combustion spraying segment dominates XX% of market share in 2024. Combustion Flame Spray Coating (also referred to as conventional thermal spray coating) uses a combustible gas as a heat source to melt feedstock in powder, wire, or rod form and accelerates the melted droplets onto the component surface. The coating is formed when the droplets impact the surface. Since heat is involved, it may be challenging to mask flame spray coatings. coatings that are moderately priced, typically possess a coarse surface finish, and typically consist of high oxide content and porosity. In a less rigorous environment, combustion spraying is a cheap alternative to using ceramic and metallic coatings.
To generate a heat source, the process relies on the chemical reaction of oxygen with a combustion fuel. A gas stream with a temperature greater than 3,000°C and well-balanced oxygen and acetylene is generated by the heat source. To generate a surface coating, a consumable usually a wire or powder is heated and forced onto a substrate.
https://www.bodycote.com/services/surface-technology/combustion-spraying/#:~:text=Process%20details,to%20form%20a%20surface%20coating. 

Two wire electrodes that are consumable and are attached to a high-current direct-current (dc) power source are supplied to the gun and touch each other in the electric arc spray process, which is also referred to as the wire arc process. This generates an arc between the electrodes that melts the tips of the wire. Because the metal is melted with all of the input energy, the process is energy efficient. A stream of air then atomizes the molten metal and pushes it in the direction of the substrate. Spray rates are driven primarily by operating current and vary as a function of both melting point and conductivity. Substrate temperatures can be very low, because no hot jet of gas is directed toward the substrate. Electric arc spraying also may be conducted with inert gases or in a controlled-atmosphere chamber.
For instance, electric arc spraying has been effectively employed in depositing corrosion-resistant coatings on oil rig parts to make them more resistant to rust and chemical corrosion in aggressive marine conditions. EuTronic Arc Spray EAS1-I, EuTronic Arc is the most productive thermal spraying process. EuTronic Arc is an Arc Spray Process employing two wires which are vaporized by an electric arc.
https://www.castolin.com/product/eutronic-arc-spray-eas1-i 
In the petroleum and gas industry, electric arc spraying is most commonly applied for the coating of larger machinery, including storage tanks, pipelines, and other structural parts. Since the coatings can be applied within a controlled environment or with the aid of inert gases, electric arc spraying can be applied where atmospheric oxygen contamination is a risk.
 

• Combustion Flame
• Electrical

Author's Detail

Ashwini Moharir

Research Analyst at Cognitive Market Research

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Enthusiastic and analytical market research professional with 2 years of hands-on experience in tracking market trends, evaluating consumer behavior, and supporting strategic decision-making. Proficient in designing surveys, conducting interviews, and synthesizing insights from both primary and secondary sources. Successfully contributed to research projects across sectors such as retail, personal care, and industrial markets. Brings a keen eye for detail, strong data interpretation skills, and a passion for uncovering what drives markets forward. Comfortable working in fast-paced environments and collaborating across departments to deliver clear, actionable findings.

Author's Conclusion