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Booming Industrial Activity and Fabrication Needs Propel U.S. Welding Consumables Market to a 4% CAGR by 2031 | TMR Insights

05-06-2025 11:57 AM CET | Chemicals & Materials

Press release from: Transparency Market Research

U.S. Welding Consumables

U.S. Welding Consumables

The U.S. welding consumables market is projected to exceed 1,925 kilo tons by 2031, expanding at a compound annual growth rate (CAGR) of approximately 4% during the forecast period. This growth reflects the increasing demand for welding materials in construction, power generation, and aerospace, driven by infrastructure development, technological advancements, and recovery in key industries post-COVID-19. With a volume surpassing 1,925 kilo tons, welding consumables are set to remain critical for fabricating robust structures and machinery through 2031.

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Understanding the U.S. Welding Consumables Market

Welding consumables, including stick electrodes, flux-cored wires, solid wires, and submerged arc welding (SAW) wires and fluxes, are essential for joining metals and thermoplastics in fabrication processes. These materials, made from raw inputs like nickel, copper, and aluminum, ensure strong, cost-effective welds while preventing oxidation and porosity. The projected volume of over 1,925 kilo tons by 2031 underscores their vital role, with flux-cored wires gaining traction for their efficiency in automated welding. The 4% CAGR highlights steady growth, supported by innovations like twin arc welding, which enhances productivity by reducing magnetic arc blow effects.

Key Drivers of Market Growth

Several factors are propelling the U.S. welding consumables market toward its 1,925 kilo ton milestone by 2031. First, the construction industry's expansion is a primary driver. Valued at US$1.3 trillion annually, per the Associated General Contractors, construction relies on welding consumables for fabricating structural steel in commercial and residential projects, consuming approximately 5 kg of welding materials per ton of steel. With infrastructure spending projected to grow 4.5% annually, this sector drives the 4% CAGR.

Second, recovery in automotive and aerospace sectors fuels demand. The U.S. aerospace industry, the world's largest, uses welding consumables for lightweight metals in aircraft, with production expected to increase 5% annually. The automotive sector, recovering from COVID-19 slowdowns, employs advanced welding for safety features, boosting consumption of high-performance wires. These trends, supported by evolving vehicle designs, align with the market's trajectory to exceed 1,925 kilo tons.

Third, technological advancements enhance efficiency. Automation and robotic welding, adopted by 30% of U.S. manufacturers in 2023, per Statista, demand metal core and flux-cored wires for precision. Innovations like Lincoln Electric's 2022 automation software reduce rework by 15%, driving investments in next-gen technologies despite slow initial adoption. These developments reinforce growth through 2031, particularly in power generation for turbines and pressure vessels.

Top Companies:

ESAB
KOBE STEEL, LTD.
Air Liquide
Illinois Tool Works Inc.
The Lincoln Electric Company
voestalpine Böhler Welding GmbH
Welding Alloys Group
Mitco Weld Products Pvt. Ltd.

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Market Segmentation and Regional Insights

The market segments by product, technology, and end-use. Flux-cored wires are expected to grow fastest, driven by robotic welding, while stick electrodes held a significant share in 2020 for their versatility. Technologies include arc welding, resistance welding, and SAW, with arc welding dominating due to its flexibility across construction and automotive applications. End-uses span building and construction (40% share in 2020), automotive, aerospace, power generation, and oil and gas, with construction leading due to infrastructure projects.

Regionally, the U.S. market is concentrated in industrial hubs like the Midwest and South, with Texas and California leading due to construction and aerospace activities. The Southwest Florida International Airport's US$250 million expansion, requiring welded structural components, exemplifies regional demand. The 4% CAGR reflects uniform growth across these hubs, supported by foreign direct investment in manufacturing and construction.

Challenges and Opportunities

The market faces challenges. Slow adoption of advanced technologies, with only 20% of welders trained in robotic systems, and raw material price volatility, fluctuating 10-15% annually, hinder growth. Competition from alternative joining methods like adhesives also poses risks. The 4% CAGR reflects a market navigating these constraints with strong industrial demand.

These challenges present opportunities. Developing eco-friendly consumables, like low-emission fluxes, could meet regulatory standards, supporting the push to 1,925 kilo tons. Expanding applications in marine and agriculture, with welding for shipbuilding and equipment repair, offers potential. Collaborations, like ESAB's 2023 welder training programs, enhance skills, while investments in automation, as seen with Illinois Tool Works, drive efficiency.

The Road to 2031

By 2031, the U.S. welding consumables market is projected to exceed 1,925 kilo tons, reflecting a decade of steady growth at a 4% CAGR. This milestone is driven by construction, aerospace, and automation trends. The market's trajectory suggests continued expansion, with welding consumables enabling robust industrial fabrication.

In conclusion, the U.S. welding consumables market demonstrates consistent growth through 2031. Surpassing 1,925 kilo tons, it addresses industrial and infrastructural needs with versatile solutions. Stakeholders-from producers like Lincoln Electric, ESAB, and Illinois Tool Works to end-users in construction and aerospace-play a vital role, ensuring welding consumables shape a durable future through 2031 and beyond.

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About Transparency Market Research

Transparency Market Research, a global market research company registered at Wilmington, Delaware, United States, provides custom research and consulting services. Our exclusive blend of quantitative forecasting and trends analysis provides forward-looking insights for thousands of decision makers. Our experienced team of Analysts, Researchers, and Consultants use proprietary data sources and various tools & techniques to gather and analyses information.

Our data repository is continuously updated and revised by a team of research experts, so that it always reflects the latest trends and information. With a broad research and analysis capability, Transparency Market Research employs rigorous primary and secondary research techniques in developing distinctive data sets and research material for business reports.

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