Interface qualification

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 caseWatch the demo, 3 min

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

Hydrogen pipeline weld, the joint a chromium barrier film protects
HydrogenCr barrier on X65 steelbreakthrough 3.7 a
Coated turbine blade from a gas turbine hot section
mock
Power and aerospace7YSZ thermal barrier on CMSX-4spallation at cycle 1 340
Cross-section of a graded ceramic to metal interlayer built by laser powder bed fusion
Additive manufacturingSapphire to Inconel 718, graded interlayerstep stress 0.63 GPa
Cross-section of a die attach layer in an electronics package
mock
ElectronicsDie attach on copperG / Gc 0.41

Six industries. One question about the interface.

Every sector below has a duty cycle library built in, so a case starts from a real service condition, not a blank form.

Hydrogen electrolyser stack
Hydrogen and ammoniaPipelines, storage, crackers and electrolysers
Sour gas wellhead
Oil and gasSour service, downhole tools, LNG cryogenic cycling
Gas turbine hot section
PowerGas turbine hot sections, nuclear instrumentation
Aero engine assembly
AerospaceEngine coatings, sensor windows, brazed assemblies
Laser powder bed fusion machine mid-build
Additive manufacturingMulti-material builds, ceramic on metal, repair
Electronics package on a wafer
ElectronicsDie attach, packaging, thin-film sensors

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

5 of 5 live

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

Analyse

2 of 7 live

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

Qualify

3 of 7 live

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

How it works

Four steps, one audit trail

  1. 01

    Describe the stack

    Choose materials from the passport library or type them in. Set the duty cycle: temperature history, pressure, environment, cycles.

  2. 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.

  3. 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.

  4. 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
The twenty-five rules in the six stages of a run, wired by the dependencies declared in the rule registry, lighting in the order they fired in case C-0412DataMismatchCriterionKineticsFractureVerdictR00R10R11R01R02R03R04R05R06R07R08R09R24R12R13R14R15R16R17R18R22R19R20R21R23

R00 · preferred value selection

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

2sourcescited in the database so far, each one resolvable by DOI
25rulesR00 to R24, unit-tested against worked cases
0blind testspublished outcomes predicted before reading them

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 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.

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.

CapabilityFE packagesCALPHAD toolsMaterials databasesConsultancy reportSurphysis
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

Public scorecard

0predictions logged

Every prediction is timestamped before the outcome is read. Hits and misses stay visible. The first campaign runs against published thermal barrier and hydrogen barrier failures.

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.

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.

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.

We reply within two working days. No mailing list.