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Thermal Spray Wires Market

Thermal Spray Wires Market Size, Share & Trends Analysis Report by Type (Pure Metal Thermal Spray Wires, Alloy Thermal Spray Wires) by Application (Manufacturing Industry, Aerospace) and Segment Forecasts, 2023-2031

Market Overview

According to Reed Intelligence the Global Thermal Spray Wires Market Size will approximately grow at a CAGR of 6.9% during the forecast period.

Thermal Spray Wires are a type of wire coated with a protective substance and then sprayed with thermal spray. Most thermal spray wires are made of stainless steel coated with copper or a nickel-copper alloy containing significant quantities of chromium and molybdenum. This form of thermal spray wire is the most prevalent. This coating protects against the environment, corrosion, and wear in applications where bare metal rapidly deteriorates. It does this by acting as a barrier.

The applications of thermal spray wires are not limited to those in the aerospace industry; rather, these wires have a wide range of potential uses, some of which include the building of bridges, the development of real estate, and mining.

The rising demand for metal thermal spray wires in various industries, such as automotive and mechanical applications, will drive the growth of this market during the forecast period. In addition, increasing investments in developing countries will fuel this market's growth globally.

Thermal Spray Wires Market Share 2019 2020 2021 2022 2023 2024 2025 2026 2028 2029 2030 2031 $XX.X Million $XX.X Million CAGR 6.9% Historical Years Forecast Years
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Market Dynamics

Market Drivers

  • Increasing Usage In the Aerospace Industry

The thermal spray material market serves a variety of end-user industries, the most important of which is the aerospace industry. The aerospace industry uses thermal spray coatings to protect components from the high temperatures and pressures experienced during flight.In addition to having strong thermal resistance and a long lifespan, they are made to safeguard the actuation systems and engine turbine blades. Most applications for thermal sprays may be found in various components of jet engines, including crankshafts, piston rings, cylinders, valves, and so on. In addition, they are utilized in coating of landing gear, which includes the bearings and axles found within, to withstand the forces applied during landing and takeoff. The market for thermal spray wire has been drying up because of the widespread use of thermal spray wire in the aerospace industry.

  • High Accuracy and Reliability In Temperature Sensing

The accuracy and dependability of thermocouple wire in temperature sensing is a strength for manufacturers since it enables them to supply consumers with a solution that can deliver precise temperature readings. Thermocouple wire, for instance, can be used in manufacturing processes that require accurate temperature control to guarantee that the process is carried out in an orderly and consistent manner.

Market Restraints

  • Negative Impact of Chemical Might Hamper Growth

A thermal spray coating results in faults such as pores, which are frequently round and take their shape during the process, blasted particles, and cracks, which form during the reduction of remaining pressures. The fouled defects are caused by either unmolded particles or partially melted. This Chemical exposure effect can hamper the growth of the thermal spray wire market.

  • Competition from Alternative Temperature Sensing Solutions

The availability of alternative temperature sensing solutions presents a challenge for manufacturers since it can potentially lower demand for thermocouple wire. For some applications, the proliferation of digital temperature sensors may decrease the demand for thermocouple wires.

Market Opportunities

  • Demand for Temperature Sensing Equipment In Various Industries Is Growing

The increasing need for temperature sensing presents an opportunity for manufacturers because it broadens the pool of prospective customers for thermocouple wire. For instance, there is an increasing demand for temperature sensors in the food and beverage business, which can present new prospects for producers.

  • Increased Demand for Automation

The increasing use of industrial automation and process control presents an opportunity for manufacturers since it drives up demand for temperature-sensing solutions like thermocouple wire. In other words, this trend creates a market for temperature-sensing solutions, creating a market for thermocouple wire. For instance, increased automation in the manufacturing business may present new opportunities for producers.

Market Scope

Report Metric Details
Market Size by 2031 USD XX Million/Billion
Market Size in 2023 USD XX Million/Billion
Market Size in 2022 USD XX Million/Billion
Historical Data 2020-2022
Base Year 2022
Forecast Period 2024-2032
Report Coverage Revenue Forecast, Competitive Landscape, Growth Factors, Environment & Regulatory Landscape and Trends
Segments Covered
  1. Segmentation by Type
    1. Pure Metal Thermal Spray Wires
    2. Alloy Thermal Spray Wires
    3. Composite Thermal Spray Wires
  2. Segmentation by Application
    1. Manufacturing Industry
    2. Aerospace
Geographies Covered
  1. North America
  2. Europe
  3. APAC
  4. Middle East and Africa
  5. LATAM
Companies Profiles
  1. Oerlikon Metco
  2. Kanthal
  3. Metallization
  4. Polymet Corporation
  5. Tankini
  6. Parat Tech
  7. Flame Spray Technologies BV
  8. Praxair Surface Technologies
  9. Plasma Powders & Systems, Inc.
  10. United Coatings Technology
  11. Allotech

Segmental Analysis

Segmentation By Type

  • Pure Metal Thermal Spray Wires

Pure metal thermal spray wires are made of pure metals such as nickel, copper, or titanium. They outperform alloy wire in terms of conductivity and corrosion resistance. Nonetheless, they lack the required flexibility to ensure that a link can be dragged out if it fails. Pure metal thermal wires connect two pieces of higher grade base material than other wires.

  • Alloy Thermal Spray Wires

Alloy thermal spray wires are cables that are specifically developed for thermal spray coating. Alloy Thermal Spray Wire is often created during manufacture to have a perfect blend of flexibility, strength, and toughness. This balance is meant to provide high-performance qualities at a low cost. The fabrication of wire begins with cold reduction, which might take the form of drawing, and is followed by the addition of alloying elements to the wire's surface.

  • Composite Thermal Spray Wires

A substance known as a composite contains two or more distinct structural layers. The term "composite" can refer to any mixture. Still, in modern usage, it is most commonly used to refer to a material composed of several different components combined to make an object that possesses particular characteristics. A common example of this would be the material known as fiberglass, in which the matrix is made of plastic, and the fibers can be made of glass, carbon fiber, or Kevlar. A composite wire that can be utilized within a wire arc spray system in addition to other similar processes.

Segmentation By Application

  • Manufacturing Industry

In mechanical engineering, thermal spray wires are used for sealing, shaping, and connecting various sheet metal components. The Thermal Spray Wire is initially brought to the liquid state by a hot wire feed system on or in close contact with the spray guns. After that, the wires are sprayed onto the surfaces that need to be fastened together with a blasting force, and then, air or water cools down to produce a strong bond. Afterward, the wires are cooled down by air or water.

  • Aerospace

Thermal spray coatings are utilized largely in the aerospace industry to protect aircraft components and repair damaged old parts. They offer great thermal resistance and have a long lifespan, which protects the engine turbine blades and actuation systems from damage. Most applications for thermal sprays may be found in various components of jet engines, including crankshafts, piston rings, cylinders, valves, and so on. In addition, they are used in the coating of landing gear (the bearings and axles contained within the landing gear) to withstand the forces exerted during takeoff and landing. For coating, thermal spray coatings like zirconium oxide, aluminum bronze, and cobalt-molybdenum are utilized in rocket combustion chambers, compressor air seals, and high-pressure nozzles, respectively.

Thermal Spray Wires Market Analysis By Type Pure Metal Thermal Spray Wires Alloy Thermal Spray Wires Composite Thermal Spray Wires By Application Manufacturing Industry Aerospace By Region North America Europe APAC Middle East and Africa LATAM Key Players Oerlikon Metco Kanthal Metallization Polymet Corporation Tankini & More ...

Regional Analysis

The Global Thermal Spray Wires Market is segmented by region as North America, Europe, Asia Pacific, Latin America, and Middle East and Africa.

North America

The thermal spray wires market share in North America is projected to comprise the largest portion overall. Demand expansion is driven mostly by its applications in the aerospace and mechanical industries because of the rapid expansion of its automobile industry. The increasing product demand from the aerospace industry in North America will ultimately increase the growth of the thermal spray wire market.


The thermal spray wire market in European countries is anticipated to be driven by growing thermal spray applications in the automotive and aerospace sectors as well as increased thermal spray usage in medical device manufacturing. The appearance of a hard trivalent chromium coating is anticipated to impede the expansion of the market. Prospects for the market's growth are anticipated to be created due to developments in spraying technology.


Asia-Pacific is expected to hold a sizeable portion of the market. Since it strongly emphasizes research and development operations, Japan has emerged as a prominent driver with increased demand from the automotive sector. In addition to being one of the largest markets for domestic airline passengers, China is also one of the largest aircraft producers in the world. Furthermore, the manufacturing industry of aviation parts and assemblies in this country has been expanding, and over 200 minor aircraft parts manufacturers are currently operating within the country. China has made major contributions to expanding the thermal spray wires market growth.

Latin America

The domestic aviation market in Brazil is the third largest in the world, and the country is home to six of the region's ten busiest airports. In addition, the nation is a leading producer of regional and business jets and a wide variety of other aerospace goods, such as turboprops, military aircraft, agricultural aircraft, business aircraft, helicopters, and other general aviation aircraft. The nation is one of the leading producers of aerospace products overall.

Thermal Spray Wires Market Regional Analysis
Regional Growth Insights Download Free Sample

Key Players

  1. Oerlikon Metco
  2. Kanthal
  3. Metallization
  4. Polymet Corporation
  5. Tankini
  6. Parat Tech
  7. Flame Spray Technologies BV
  8. Praxair Surface Technologies
  9. Plasma Powders & Systems, Inc.
  10. United Coatings Technology
  11. Allotech

Recent Developments

June 2, 2023- The National Institute for Occupational Safety and Health (NIOSH) developed a thermal spray coating aerosol generator and inhalation exposure system. Thermal spray coating involves melting a product at high temperatures and spraying it on a surface under pressure. The procedure generates large amounts of complex metal aerosol (Fe, Cr, Ni, and Zn), which poses a serious risk to the operator. NIOSH develops and tests an automated thermal spray coating aerosol generator and inhalation exposure system. It simulates workplace exposures. A closed room for spray coating and an exposure chamber with measurement equipment and controls included an electric arc wire-thermal spray coating aerosol generator and exposure system.

Thermal Spray Wires Market Segmentations

Segmentation by Type

  • Pure Metal Thermal Spray Wires
  • Alloy Thermal Spray Wires
  • Composite Thermal Spray Wires

Segmentation by Application

  • Manufacturing Industry
  • Aerospace

Frequently Asked Questions

What is the estimated growth rate (CAGR) of the global thermal spray wires market?
The global thermal spray wires market growing at a CAGR of 6.9% from (2023–2031).
North america region has the expected to dominate the market.
Segment by type (Pure Metal Thermal Spray Wires, Alloy Thermal Spray Wires, Composite Thermal Spray Wires) Segment by application (Manufacturing Industry, Aerospace) and region (North America, Europe, Asia Pacific, etc).
The forecast period for this market report is between 2023-2031.
Increasing usage in the aerospace industry, high accuracy and reliability in temperature sensing are the key drivers for the growth of the market.

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