ITSA Scholarship Winners Drive Thermal Spray Innovations

From advancing polymer-based cold spray technologies to improving the reliability of coating performance and testing, the 2025 ITSA Scholarship recipients represent the next generation of innovation in thermal spray. Each brings a unique perspective rooted in rigorous research, hands-on experience, and a commitment to real-world impact while sharing a common goal: pushing the boundaries of materials engineering and translating scientific discovery into durable, high-performance solutions across critical industries.

Antonio Colao

Antonio Colao’s path into thermal spray began with curiosity and quickly turned into a clear sense of purpose. After completing his undergraduate degree in engineering science with a concentration in mechanical engineering at Stony Brook University, Stony Brook, N.Y., he chose to continue his studies there in materials science and engineering, immersing himself in research at the university’s Center for Thermal Spray Research (CTSR).

It was at CTSR that Colao discovered the true scope and impact of thermal spray technology. Initially introduced to the lab by CTSR Director Dr. Sanjay Sampath, he recalled his first exposure as both overwhelming and compelling. Seeing a range of processes, from advanced coating systems to thermal-sprayed thermocouples and even legacy equipment that traced the field’s evolution, offered a glimpse into what he described as the “limitless possibilities” of the discipline.

That impression deepened during his first Consortium for Thermal Spray Technology meeting, where conversations with industry professionals highlighted how relatively small coatings can deliver outsized gains in performance and durability. One example that stood out involved extending the life of mining equipment at a fraction of replacement cost, an experience that cemented his understanding of thermal spray as a powerful, real-world engineering solution.

“What continues to interest me is how these relatively modest coatings can have such a large impact on a component’s performance and longevity,” Colao said. At the same time, he points to the field’s process-sensitive nature as both its greatest challenge and opportunity. “It opens the door to constant problem solving.”

Colao’s research reflects that mindset. His graduate work focuses on the repeatability of tensile adhesion testing (TAT), a critical issue in evaluating coating performance. By systematically studying variables such as processing conditions, adhesive systems, and failure modes, he aims to better understand sources of variability and improve the reliability of testing methods. His work has included testing ceramic coatings such as yttria-stabilized zirconia and titania across different substrates and processes, supported by detailed data analysis and statistical evaluation.

In parallel, he has explored other applications, including embedded thermal-sprayed thermocouples used to measure temperature gradients within thermal barrier coatings under plasma exposure. Together, these experiences have given him a broad, hands-on perspective on both the science and application of thermal spray systems.

Since receiving the ITSA Scholarship, Colao’s trajectory has continued to accelerate. He described the award as both an honor and validation of his direction. “It reinforced my commitment and showed me how valuable academic research is to the industrial community,” he said. The support and confidence have enabled him to deepen his research and engagement within the field.

One milestone came when he returned to the Consortium for Thermal Spray Technology meeting not as a newcomer, but as a presenter. Selected to share his findings on adhesion-
testing variability, he noted the contrast of feeling overwhelmed at his first meeting to confidently presenting research just months later.

Beyond academia, Colao has also gained industry experience through an internship with ReliaCoat Technologies, where he plans to continue contributing as his studies progress. The role has strengthened his understanding of real-world applications and sharpened his interest in coating metrology, standards development, and measurement techniques — areas he sees as central to the field’s future.

Looking ahead, Colao envisions a career rooted in advancing thermal spray through both technical rigor and applied problem-solving. Whether in industry or collaborative research settings, he hopes to work on projects that improve coating reliability, refine testing standards, and bridge the gap between laboratory research and industrial practice.

For students considering the field, his advice reflects his own experience: progress comes through consistency. “Every day you spend learning adds real value,” he explained. “Those small gains compound over time.” While the early stages can feel overwhelming, he emphasized the importance of patience, curiosity, and trusting the long-term process.

With a growing body of research, hands-on experience, and a clear focus on practical impact, Colao is building a career that reflects the core strengths of thermal spray itself — precision, resilience, and the ability to deliver lasting performance in demanding environments.

Suleiman Muktari

From the start of his academic journey, Suleiman Muktari has been driven by a fascination with how materials behave under extreme conditions — 
how they endure heat, radiation, stress, and, ultimately, how they fail. That curiosity now defines his work as a third-year PhD student in mechanical and materials engineering at Florida International University, Miami, Fla., where his research sits at the intersection of materials science, surface engineering, and sustainability.

Muktari focuses on cold spray additive manufacturing of polymer-based composite coatings, an emerging and rapidly evolving area within the thermal spray field. What draws him to thermal spray is its ability to transform materials science into real engineering solutions by designing surfaces capable of withstanding harsh service environments across applications such as aerospace propulsion, marine corrosion protection, and radiation-
intensive systems.

Unlike traditional thermal spray processes, cold spray relies on the kinetic energy of high-velocity particles rather than heat, making it especially promising for polymers, which are often vulnerable to thermal degradation. Muktari is particularly interested in pushing this technology beyond its conventional metallic applications to create lightweight, high-performance polymer composite coatings with enhanced mechanical strength, thermal stability, and multifunctionality.

“The challenge,” he noted, “is that polymer cold spray is still an emerging science.” Polymers behave very differently under high-velocity impact, with bonding mechanisms highly sensitive to temperature, particle velocity, surface conditions, and molecular structure. Understanding these relationships requires a combination of experimental work, thermal analysis, and modeling — complexities that Muktari sees not as obstacles, but as motivation.

His research aims to establish fundamental process-structure-
property relationships for these materials. Recent work has focused on thermodynamics and crystallization kinetics, examining how cold spray processing influences molecular ordering and crystallinity — key factors in determining the strength and long-term performance of polymer coatings. He is also investigating particle bonding and deformation mechanisms in composite systems, helping define how advanced coatings can be engineered for demanding structural and protective applications.

That work has already yielded promising results, including coatings with high deposition efficiency, improved hardness, and enhanced crystallinity. Just as importantly, it is helping position polymer composite cold spray as a viable pathway for next-generation lightweight materials solutions.

Recognition from ITSA has reinforced that trajectory. Muktari describes receiving the ITSA Scholarship as both an honor and a turning point. “It was more than financial support,” he said. “It was a signal that the community sees value in this direction of research.” The award has strengthened his confidence, expanded his professional network, and supported his ability to share his work through publications and conferences.

Beyond the lab, Muktari is actively engaged in the broader materials community. Through his involvement with the ASTM student chapter, he has participated in standards discussions and interdisciplinary initiatives that connect academic research with industrial practice. His selection to the ASTM International Emerging Professionals Program in 2025 further deepened his understanding of how research transitions into real-world applications through collaboration and standards development.

Looking ahead, Muktari plans to build a career that bridges research, innovation, and application. Whether in industry, national laboratories, or academia, he is particularly interested in roles that translate laboratory-scale discoveries into practical engineering solutions across sectors such as aerospace, automotive, marine systems, and energy. Long term, he hopes to lead a research program focused on advanced manufacturing, multifunctional materials, and sustainable coating technologies while also mentoring future engineers.

For students considering the field, his advice is straightforward: be curious and patient. Thermal spray, he emphasized, is more than a coating process; it is a platform for solving complex, real-world problems. “The key is to build strong fundamentals and understand how processing connects to performance,” he shared. “That’s where the real value lies.”

Muktari’s work is guided by a clear vision: expanding the possibilities of cold spray technology and developing materials that not only withstand extreme environments but also help create more efficient, durable, and sustainable engineering systems.

Apply Now for 2026 Scholarships

ITSA awarded three scholarships in 2025. Emmanuel Aikulola from North Carolina State University, Raleigh, N.C., was the third recipient.

To learn more about ITSA scholarships and apply for the 2026 awards, see page 15 of this issue and visit thermalspray.org.

CINDY WEIHL (cweihl@aws.org) is editor-in-chief of SPRAYTIME.