The Global Electric Arc Spray Coatings Market was valued at USD 7.14 Billion in 2024 and is projected to reach USD 10.89 Billion by 2030, growing at a Compound Annual Growth Rate (CAGR) of 6.8% during the forecast period (2024–2030). This expansion is fueled by the escalating demand for durable and corrosion-resistant coatings across critical industries such as Aerospace, Automotive, and Energy, coupled with technological advancements in thermal spray processes that enhance coating performance and application efficiency.

As industries worldwide prioritize asset protection and lifecycle extension, the focus intensifies on the key manufacturers and innovators providing robust coating solutions. This blog profiles the Top 10 Companies in the Electric Arc Spray Coatings Industry—a collection of established material specialists and application technology leaders shaping the future of surface engineering.

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🔟 1. Oerlikon Metco

Headquarters: Pfäffikon, Switzerland
Key Offering: MetcoArc electric arc spray systems, a wide portfolio of coating wires (Zn, Al, stainless steels, MCrAlYs)

Oerlikon Metco is a global powerhouse in surface solutions, offering a comprehensive range of electric arc spray equipment and consumables. Their technology is renowned for high deposition rates and is extensively used for corrosion protection, dimensional restoration, and thermal barrier coatings in demanding environments.

Innovation & Sustainability Initiatives:

• Development of advanced wire alloys for enhanced wear and corrosion resistance

• Focus on process automation and digitalization for improved repeatability and reduced waste

• Commitment to sustainable manufacturing practices and recyclable material options

Download FREE Sample Report: Global Electric Arc Spray Coatings Market – View in Detailed Research Report

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9️⃣ 2. Praxair Surface Technologies (Now part of Linde)

Headquarters: Danbury, Connecticut, USA
Key Offering: TAFA electric arc spray systems, performance coating wires (including 83MV, 95MXC), and technical services

Following its acquisition by Linde, Praxair Surface Technologies (PST) remains a leading provider of thermal spray solutions. Their TAFA brand is synonymous with reliability in electric arc spraying, serving industries that require high-performance coatings for extreme conditions, such as aerospace turbine components and industrial machinery.

Innovation & Sustainability Initiatives:

• Pioneering nickel- and cobalt-based alloy wires for high-temperature applications

• Integration into Linde’s broader industrial gases portfolio for synergistic growth

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8️⃣ 3. TOCALO Co., Ltd.

Headquarters: Kobe, Japan
Key Offering: Custom electric arc spray coating services, specialized surface treatment solutions

TOCALO is a major Japanese surface treatment specialist with a significant global presence. The company excels in providing tailored electric arc spray coatings, particularly for the semiconductor and electronics sectors, where precision and contamination control are paramount.

Innovation & Sustainability Initiatives:

• Expertise in applying coatings for semiconductor manufacturing equipment

• Continuous R&D in coatings for erosion and chemical resistance

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7️⃣ 4. Falmer Thermal Spray

Headquarters: Waterlooville, United Kingdom
Key Offering: On-site and in-shop electric arc spray coating services, corrosion protection systems

Falmer Thermal Spray is a prominent service provider in Europe, specializing in both electric arc and flame spray applications. They are particularly well-known for large-scale corrosion protection projects on infrastructure like bridges, offshore platforms, and power generation facilities.

Innovation & Sustainability Initiatives:

• Leadership in applying zinc and aluminum coatings for long-term asset protection

• Investment in mobile application units for on-site servicing

Download FREE Sample Report: Global Electric Arc Spray Coatings Market – View in Detailed Research Report

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6️⃣ 5. ASB Industries (A Subsidiary of A&M Industrial)

Headquarters: Barberton, Ohio, USA
Key Offering: ArcAlloy electric arc spray wires and coating services, abrasive blasting equipment

ASB Industries is a key North American player, offering a blend of high-quality consumables and expert application services. Their ArcAlloy wires are widely used for rebuilding worn parts and applying protective coatings in the pulp and paper, steel, and mining industries.

Innovation & Sustainability Initiatives:

• Development of proprietary cored wires for specialized applications

• Focus on providing complete surface preparation and coating solutions

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5️⃣ 6. Plasmajet

Headquarters: Marly, Switzerland
Key Offering: Electric arc spray pistols, automated spray systems, and retrofit solutions

Plasmajet specializes in the design and manufacture of thermal spray equipment, including robust electric arc spray guns. They are recognized for their ergonomic and durable gun designs that offer excellent operator control and consistent coating quality for manual and automated applications.

Innovation & Sustainability Initiatives:

• Innovations in gun cooling and wire feeding mechanisms for extended operation

• Solutions for integrating electric arc spray into robotic work cells

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4️⃣ 7. A&A Thermal Spray

Headquarters: Houston, Texas, USA
Key Offering: Comprehensive thermal spray coating services, including electric arc spray for oil & gas and petrochemical sectors

A&A Thermal Spray is a leading service provider with a strong footprint in the energy sector. They utilize electric arc spraying to protect critical components from corrosion and wear in refineries, pipelines, and offshore installations, helping to extend equipment life significantly.

Innovation & Sustainability Initiatives:

• Specialization in coatings for sour service (H2S) environments

• Implementation of stringent quality control measures per industry standards

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3️⃣ 8. MBI Coatings (Brand of Metallic Bonds)

Headquarters: Racine, Wisconsin, USA
Key Offering: MBI electric arc spray wires, thermal spray powders, and application services

MBI Coatings is a significant manufacturer of thermal spray consumables, with a solid reputation for its electric arc spray wires. Their products are used for a variety of applications, from coating rolls in the printing industry to protecting structural steel.

Innovation & Sustainability Initiatives:

• Production of a wide range of metal and cored wires

• Commitment to consistent wire quality and diameter control

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2️⃣ 9. TST Coatings

Headquarters: Houston, Texas, USA
Key Offering: Electric arc and thermal spray coating services for industrial maintenance

TST Coatings is a specialized service company focused on protecting industrial assets. They are experts in applying electric arc spray coatings for corrosion prevention on large structures, including water treatment plants, bridges, and chemical processing equipment.

Innovation & Sustainability Initiatives:

• Expertise in complying with industrial specifications like NACE and SSPC

• Use of advanced inspection techniques to ensure coating integrity

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1️⃣ 10. Bodycote

Headquarters: Macclesfield, United Kingdom
Key Offering: A broad portfolio of surface technology services, including thermal spray coatings

As one of the world’s largest thermal processing services providers, Bodycote offers electric arc spray coatings as part of its extensive capabilities. Their global network of facilities provides localized support to aerospace, automotive, and energy customers requiring high-integrity coatings.

Innovation & Sustainability Initiatives:

• Investment in R&D for coating solutions that improve component efficiency and durability

• Global quality standards and certification across their service centers

Get Full Report Here: Global Electric Arc Spray Coatings Market – View in Detailed Research Report

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🌍 Outlook: The Future of Electric Arc Spray Coatings Is Smarter and More Integrated

The electric arc spray coatings market is experiencing a significant evolution. While traditional corrosion protection remains a core application, the industry is increasingly adopting advanced materials, robotics, and digital monitoring to deliver higher-value solutions.

📈 Key Trends Shaping the Market:

• Growing demand for cored wires that allow for custom alloy compositions and enhanced properties

• Increased integration of robotics and automation for improved coating uniformity and reduced labor costs

• Expansion into additive manufacturing (3D printing) for part repair and near-net-shape manufacturing

• Rising focus on environmentally preferable materials and processes

Get Full Report Here: Global Electric Arc Spray Coatings Market – View in Detailed Research Report

The companies listed above are not only protecting critical assets across the globe—they are driving the technological evolution of industrial surface engineering.