Abhijith Sukumaran, Ph.D.

Product Manager

Jupiter, Florida, United States7 yrs 9 mos experience
Highly Stable

Key Highlights

  • Expert in advanced coating systems for aerospace applications.
  • Led NASA projects achieving TRL 7 for lunar exploration.
  • Published over 20 research papers and filed 3 patents.
Stackforce AI infers this person is a highly skilled Coating Process Engineer specializing in aerospace materials and surface engineering.

Contact

Skills

Core Skills

Coating ProcessesMaterials Development

Other Skills

3D Computer Aided Design (3D CAD)ADVANCED DESIGN SYNTHESISAPSAUTOMOBILE DESIGNAUTOMOBILE NEW DRAWINGS AND DESIGNSAUTOMOBILE PART DEVELOPMENTAerospaceAerospace ManufacturingAluminumAutoCADAutoCAD MechanicalBIO TRIBOLOGYCommunicationDESIGN OF PRESSURE VESSELS AND PIPINGSDESIGN OF TRANSMISSION ELEMENTS

About

πŸš€ Coating Process Engineer:" PSM LLC | Materials Scientist | NASA Fellow πŸ›°οΈ Ph.D. in Materials Science & Engineering with expertise in coating systems, advanced materials, and surface engineering for extreme environments. Currently working in the IGT field, specializing in TBC and EBC coating processes for gas turbine components, integrating research-driven innovations with industrial applications. Professional Experience Coating Process Engineer | IGT Industry Specialize in coating systems and manufacturing for gas turbine components. Serve as the primary technical contact for coating suppliers, leading process development. Conduct process reviews, supplier audits, and root cause analysis (NCRs). Collaborate with IPT teams to drive quality improvements and ensure seamless communication. Develop and maintain coating specifications and technical documentation. Spearhead new coating material R&D for enhanced performance in extreme environments. Support cost reduction initiatives and optimize materials for improved lifecycle performance. Doctoral Research | NASA ECI Research Fellow Led NASA collaborations to develop Ti-BN thermal spray coatings for lunar/Martian applications, achieving NASA TRL 7 and ISS testing. Specialized in thermal spray (Plasma, Cold Spray), electrodeposition, and sputter coatings. Developed coatings for MISSE-17 exposure at the International Space Station for radiation and wear resistance. Managed Plasma Forming Laboratory, leading research teams in process optimization. Developed cold-sprayed metallic/polymer composites for defense/aerospace applications. Researched lunar simulant sintered parts, ultra-high temperature ceramics, and polymer-2D materials for radiation shielding. Published 20+ research papers, 3 patents, featured in International Thermal Spray & Surface Engineering Magazine. Education Ph.D. in Materials Science & Engineering, Florida International University M.S. in Machine Design B.S. in Mechanical Engineering Technical Expertise Coating Processes: Plasma Spray, Cold Spray, HVOF, Aluminide, Electrodeposition, Sputter Coatings Materials Development: High-temp alloys, Ceramics, Polymer Composites, Nano composites Surface Engineering: Tribology, Erosion, Radiation, Corrosion Studies, Space & Implant Tribology Characterization: SEM, XRD, TEM, XPS, Tribometry, Erosion Testing, XRD, AFM, Eddy Passionate about materials innovation, surface engineering, and process optimization, I seek to advance manufacturing and aerospace technologies. Let’s connect! πŸ“© Email: ksabhijith729@gmail.com | πŸ“ž Phone: +1 786-312-0426

Experience

Power systems mfg., llc, a hanwha company

Coating Process Engineer

Feb 2025 – Present Β· 1 yr 1 mo Β· Jupiter, Florida, United States Β· On-site

  • Senior Coating Process Engineer/ Materials Scientist
  • Feb 2025- Present
  • Specialized in high temperature coatings/ materials systems and manufacturing processes for gas turbine
  • components within the IGT hardware domain. Served as the primary technical contact for coating suppliers and
  • led process development initiatives for thermal barrier (TBC) YSZ; NiCoCrAlY, environmental barrier (EBC),
  • dense vertically cracked (DVC) ,abradable, aluminide and low K coatings.
  • Design and Develop novel coatings for ammonia based gas turbines
  • Developed and maintained comprehensive coating specifications and technical documentation for production.
  • Spearheaded research and development of new coating material formulations to drive innovation and enhance
  • performance in extreme environments.
  • Failure Evaluation: Aero foils, Vanes, Shrouds, Transition pieces, Weld assessments, EDM cooling hole
  • evaluations
  • Conducted process reviews and supplier audits, addressing non-conformance/ failure mode issues through
  • rigorous root cause analysis and corrective actions (NCR). Collaborated with Integrated Product Teams (IPT)
  • to drive quality improvements and ensure effective cross-functional communication.
  • Supported cost reduction initiatives and improved lifecycle performance through innovative materials and
  • process optimizations.
high temperature coatingsthermal barrier coatingsenvironmental barrier coatingsroot cause analysissupplier auditsprocess development+6

Florida international university

Graduate Reserach Assistant

Jan 2021 – Feb 2025 Β· 4 yrs 1 mo

  • Worked on 25M+ dollar research projects funded by NASA, ARL and Federal funding
  • Led a Team of 3 NASA centers, FIU, and Plasma Process LLC. in developing novel Ti-BN thermal spray
  • coatings for Lunar and Martian extreme environments, for lunar rovers and structures against wear, erosion,
  • corrosion and space radiation. Developed coatings obtained NASA TRL-Level 7 and went to International
  • Space Station for Real Life Exposure. Ph.D. research recognized worldwide: International thermal spray and
  • surface engineering magazine cover page and featured article
  • Led the development of advanced Thermal Barrier Coatings (TBCs), including NiCrAlY, alumina, and High
  • Entropy Alloys (HEAs), for gas turbine components
  • Pioneered the development of cold-sprayed metallic and polymer composites as SMART materials in In-situ
  • resource utilization for defense and aerospace applications.
  • Developed and Characterized Lunar simulant sintered parts for in-situ resource utilization and ultra-high
  • temperature ceramics for high-performance aerospace applications.
  • Published numerous research papers (20+6) in top-tier journals, presented findings at international
  • conferences, and filed three commercialized patents on erosion test rigs, cold-sprayed polymer composites,
  • and flash temperature measurement system
thermal spray coatingsNASA collaborationshigh entropy alloyscold-sprayed compositesresearch paperspatents+3

Council for scientific and industrial research (csir)

JUNIOR RESEARCH FELLOW

Jun 2020 – Jan 2021 Β· 7 mos

  • Designed and developed an advanced electrodeposition setup for iridium and corrosion resistant coatings on
  • aerospace components, focusing on optimizing coating processes for high-temperature and oxidation-resistant
  • applications
electrodepositioncorrosion resistant coatingscoating processes optimizationCoating Processes

Indian institute of technology, madras

Junior Research Fellow

Feb 2019 – Jan 2020 Β· 11 mos Β· Chennai Area, India

  • Developing advanced multilayer nano silicon nitride, DLC and zirconium coatings with surface texture to
  • enhance hip implant performance. Innovating nitrided coatings to improve bio-tribocorrosion resistance.
  • Reducing guide shoe noise with hollow guide rails for KONE Elevators. Analyzing polymer composite wear in
  • excavator buckets for CATERPILLAR Inc. Evaluating brake torque fade in elevator brakes for KONE Ltd. over
  • 2 million duty cycles.
multilayer coatingsbio-tribocorrosion resistancepolymer composite wear analysisMaterials Development

Arihant honing and finishing technology pvt ltd

Mechanical engineer

Jun 2015 – Jul 2016 Β· 1 yr 1 mo Β· Mubai

Education

Florida International University

Doctor of Philosophy - PhD β€” Material science and engineering

Jan 2021 – Feb 2025

College of Engineering Trivandrum

Master of Technology - MTech β€” Mechanical Engineering

Jan 2016 – Jan 2018

caarmel engineering college

Bachelor of Technology - BTech β€” mechanical engineering

Aug 2011 – Jul 2015

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