Surface Physics Analysis

Will this joint, coating or barrier survive its duty cycle?

Give Surphysis the layer stack, the duty cycle and your own characterisation files. It returns the fracture margin, the breakthrough time and the survival probability, with the one measurement that would change the answer.

Run a case Watch the demo, 3 min

Free for academic labs. No AI at runtime: every number comes from a numbered physics rule you can audit.

Live case

HydrogenPowerAdditiveElectronics

Cr barrier on X65 pipeline steel

7 MPa H2, 50 °C, 20 a

Cr barriercritical interface150 nm
X65 pipeline steelbulk

Hydrogen enters along the grain boundaries of the barrier filmBreakthrough3.7 aR13

7YSZ thermal barrier on CMSX-4

1100 °C, 1 500 cycles

7YSZ top coat180 µm, columnar
Thermally grown oxidecritical interface4.2 µm
NiCoCrAlY bond coat120 µm
CMSX-4 substratesingle crystal

A crack advances along the thermally grown oxide until the coat lets goSpallationcycle 1 340mock

Sapphire to Inconel 718, graded interlayer

1 200 K excursion, 5 laser pulses

Sapphirec-plane
MoO2 anchorcritical interface50 nm
Graded interlayer5 steps, 3.2 µm
Cr barrier150 nm
Inconel 718laser built

A temperature front crosses the stack; the graded steps hold, the barrier does notStep stress0.63 GPaR05

Die attach on a copper substrate

−40 to 150 °C, 1 000 cycles

Silicon die0.3 mm
Attach layercritical interface40 µm
Copper substratebulk

Thermal cycling drives a crack along the attach layerFracture marginG / Gc 0.41mock

What a verdict reads like

One page. The weakest interface, its life, and what to measure next.

No score out of ten. A named interface, a named mechanism, a number with its band, and the assumption that most controls it. Written for the engineer who has to sign.

Read a full sample report

Verdict · case C-0412engine 0.1 · mock data

Sapphire to Inconel 718, graded interlayer, LPBF

Conditional pass

Weakest interface Chromium barrier, consumed by grain-boundary diffusion of Ni	1.0 pulses
Survival over 5 pulses Monte Carlo, 4 000 draws	P = 0.01
Interlayer step stress Minimax grading, 5 steps	0.63 GPa · pass
Fracture margin Edge delamination, Al2O3 to step 1	G / Gc 0.027 · pass

Measure nextD0_gb by permeation or diffusion couple. Accepted: .csv t and J. Alternative: coarsen the barrier grains by a pre-build anneal and re-run.

How it works

Four steps, one audit trail

01
Describe the stack
Choose materials from the passport library or type them in. Set the duty cycle: temperature history, pressure, environment, cycles.
02
Attach what you measured
XRD as .xy or .xrdml, EBSD as .ctf or .ang, SEM as .tif with a scale bar, permeation as .csv. Each file tightens a prior.
03
Watch the engine reason
Stress, minimax grading, fracture, grain-boundary kinetics and Sobol sensitivity run as numbered rules. Every step is logged with its rule reference.
04
Take the verdict to the bench
Fracture margin, breakthrough time, survival probability, a ranked measure-next list, and the recipe as editable code with an acceptance test plan.

The engine

Physics you can audit. No AI at runtime.

Twenty-five numbered rules cover thermo-elastic mismatch, minimax graded interlayers, grain-boundary diffusion, interface fracture mechanics and global sensitivity. Each rule cites its equation and its sources; each run prints the numbers it used.

Continuum mechanics and fractureBiaxial mismatch stress, minimax step rule, Hutchinson and Suo energy release rates, mode-mixity toughness
Microstructure and kineticsScherrer and Williamson-Hall grain size, Hart effective diffusivity, Harrison regimes, barrier breakthrough
Uncertainty that ranks the next measurementMonte Carlo over stated error bars, Saltelli Sobol indices, measure-next by variance reduction per cost

R00 · preferred value selection

Stages left to right; every line is a dependency declared in the rule registry.

41property rowseach with its source, method, form and temperature window, from 7 references

25rulesR00 to R24, every one unit-tested against a worked case

7duty cyclesreal service conditions, so a case starts from the environment the part sees

Why Surphysis

The tools you own stop at properties or at stress. The verdict lives in between.

Surphysis runs on top of the simulation and database tools you already have. It replaces the six-week consultancy report, not your stack.

Capability	FE packages	CALPHAD tools	Materials databases	Consultancy report	Surphysis
The interface is the unit of analysisIts own passport, toughness data and life verdict
Your measurement files move the answerXRD, EBSD, SEM, permeation tighten the priors
Barrier life from grain-boundary kineticsBreakthrough time, not thickness alone
Ranked measure-next listWhich instrument, which sample, how much it tightens the verdict
Public scorecard of blind predictionsHit and miss record against published failures
Answer in minutes, in the browserData stays on your machine until you export

built in possible with expert work not offered

Nineteen services, three doors

Design it, analyse what you built, qualify it for service

Each service is a chain of numbered rules. 10 are live today; the rest are in validation and open a request, never a dead end.

Design

before the bench

5 of 5 live

Choose materials and a stack that will survive, and the process window that makes it.

Analyse

your own measurements

2 of 7 live

Attach XRD, EBSD, SEM or permeation files. Each one tightens a prior and moves the verdict.

Qualify

for the auditor

3 of 7 live

Turn the verdict into the documents a qualification review expects, in the wording it expects.

Industries

Six sectors. One question about the interface.

Each sector opens on a real service condition from the duty cycle library, so a case starts from the environment the part actually sees, not a blank form.

Hydrogen and ammonia

Pipelines, storage, crackers and electrolysers

Temperature: 50 °C
Pressure: 7 MPa
Duration: 20 a hold
Environment: H2

Oil and gas

Sour service, downhole tools, LNG cryogenic cycling

Temperature: 120 °C
Pressure: 35 MPa
Duration: 10 a hold
Environment: H2S 10 kPa partial pressure, brine

Power

Gas turbine hot sections, nuclear instrumentation

Temperature: 27 to 1100 °C
Pressure: 2 MPa
Duration: 1 500 cycles
Environment: combustion gas

Aerospace

Engine coatings, sensor windows, brazed assemblies

Temperature: 27 to 900 °C
Pressure: 0.8 MPa
Duration: 3 000 cycles
Environment: combustion gas

Additive manufacturing

Multi-material builds, ceramic on metal, repair

Temperature: 627 to 1220 °C
Pressure: ambient
Duration: 5 cycles
Environment: argon, 100 ppm O2

Electronics

Die attach, packaging, thin-film sensors

Temperature: -40 to 150 °C
Pressure: ambient
Duration: 1 000 cycles
Environment: air

Scored in public

Every prediction is timestamped before the published outcome is read, and misses stay on the board with the rule that caused them. No incumbent publishes a record like this.

0 of 40 logged
TBC spallation and hydrogen barrier breakthrough, opens 2026-10

Your data stays yours

Uploads are parsed in your browser. Nothing leaves your machine until you export a report. No model is trained on your files, because there is no model.

Runs in the browser. No account needed to try a case.

Built from the literature

Every property carries its source, method, form and temperature window. Disputed values stay disputed and widen the band rather than pick a side.

Every value in a verdict traces to a citation you can open.

Request a demo session

Bring one interface you worry about. We run it live.

Forty minutes on a call. You describe the stack and the duty cycle, we run the case in front of you and hand you the verdict report afterwards. Academic labs get an account on the same call.

BeforeSend the layer stack and the duty cycle, or bring them to the call. Characterisation files are welcome and not required.
On the callWe build the case in front of you and run it. You see every rule fire, with the numbers it used and the assumptions it made.
AfterwardsThe verdict report, the assumptions table and the ranked measure-next list, by email the same day. Yours to circulate.