The U.S. thermal spray coating for oil and gas market size is expected to reach USD 426.3 million by 2027, expanding at a CAGR of 7.8% over the forecast period, according to a new study by Grand View Research, Inc. Increasing demand corrosion inhibitors from oil rigs in U.S. is significantly driving the market growth.

Thermal coatings are used in a variety of applications including oil and gas, aerospace, petrochemical, marine, and automotive. There are a variety of coatings available that can be used depending upon the specific requirements of the industry. For instance, electric arc wire spray is used for industrial gas turbines, whereas oil and gas industry uses High Velocity Oxygen Fuel (HVOF) and atmospheric plasma spray.

The product demand from downstream industrial segment is expected to increase steadily on account of their increasing use, primarily in numerous products such as gasoline, diesel, pesticides, pharmaceutical, propane, liquid petroleum gas, plastics, and jet fuel. The expansion of downstream segment, particularly in the industrial cities such as Houston, New York, Chicago, Los Angeles, Dallas, and St. Louis, is expected to have a positive impact on the market over the forecast period.

Based on product segment, metal is anticipated to register a significant growth over the forecast period. Metals such as zinc, bronze, aluminum, and copper are used in thermal spraying processes. These methods are utilized in various components across the oil and gas industry, which include pump impellers, casings, pipes, mud pump components, and gate valves. If a material can be heated to its melting point without it boiling away, the materials can be used for spraying. A wide range of steel materials can also be used for corrosion and wear protection in thermal spraying applications.

The flame spray technology segment is anticipated to expand at the fastest growth rate over the forecast period. This process produces surface coatings by using heat from burning oxygen with fuel gas. It is done in order to melt the coating material, which is then propelled onto a substrate. The process is often used as a cost-effective alternative for ceramic and metallic coatings. The process uses a wide variety of ceramic or metallic coatings including molybdenum, stainless steel, low carbon steel, aluminum, zinc, bronze, and nickel-based materials.

Further key findings from the report suggest:

  • Carbides is expected dominate the product segment during the forecast period owing to its erosion and abrasion resistant properties
  • Flame spray is the fastest growing application segment in the market on account of growing demand thermal coatings from oil and gas industry
  • HVOF was the leading technology segment in 2019 owing to its benefits such as reduced cost, improved performance, and improved electrical properties
  • Some of the key players in the market are Praxair Surface Technologies, Inc.; Metallization Ltd.; Flame Spray Coating Co.; Precision Coatings, Inc.; Montreal Carbide Co. Ltd.; Kennametal Inc.; and Oerlikon Metco