Hydrogen and ammonia
Pipelines, storage, crackers and electrolysers
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.
Free for academic labs. No AI at runtime: every number comes from a numbered physics rule you can audit.
Inconel 718 built on sapphire, graded interlayer
R051 200 K excursion, 5 laser pulses
- Inconel 718laser built
- Cr barrier150 nm
- Graded interlayer5 steps, 3.2 µm
- MoO2 anchorcritical interface50 nm
- Sapphirec-plane substrate
Cr barrier on X65 pipeline steel
R137 MPa H2, 50 °C, 20 a
- Cr barriercritical interface150 nm
- X65 pipeline steelbulk
7YSZ thermal barrier on CMSX-4
mock1100 °C, 1 500 cycles
- 7YSZ top coat180 µm, columnar
- Thermally grown oxidecritical interface4.2 µm
- NiCoCrAlY bond coat120 µm
- CMSX-4 substratesingle crystal
Die attach on a copper substrate
mock-40 to 150 °C, 1 000 cycles
- Silicon die0.3 mm
- Attach layercritical interface40 µm
- Copper substratebulk
Industries
Six sectors. One question about the interface.
A case begins from the environment the part actually sees, not a blank form. You set the duty cycle from your own service record on the first screen, and the engine works to it.
Oil and gas
Sour service, downhole tools, LNG cryogenic cycling
Power
Gas turbine hot sections, nuclear instrumentation
Aerospace
Engine coatings, sensor windows, brazed assemblies
Additive manufacturing
Multi-material builds, metal on ceramic, repair
Electronics
Die 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
before the bench
Choose materials and a stack that will survive, and the process window that makes it.
- Material passportEvery property with source, method and error barlive
- Mismatch checkThermal and elastic mismatch, minimax step stresslive
- Stack designerStep count, thicknesses, recipe as codelive
- Pair mapWhich ceramic meets which metal, and with what anchorlive
- Process windowTemperature and ramp region where every rule passeslive
Analyse
your own measurements
Attach XRD, EBSD, SEM or permeation files. Each one tightens a prior and moves the verdict.
- Measurement readerGrain size, residual stress, thickness from your fileslive
- Barrier lifeGrain-boundary breakthrough time, survival probabilitylive
- Fracture verdictDelamination and channelling margin by mode mixityin validation
- Chemistry checkDoes the oxide or barrier form and stay stablein validation
- Failure investigationRanked hypotheses and the discriminating measurementin validation
- Datasheet comparatorVendor datasheet against design intentin validation
- Repair-cycle lifeRemaining life after each repairin validation
Qualify
for the auditor
Turn the verdict into the documents a qualification review expects, in the wording it expects.
- Uncertainty and measure-nextSobol ranking of what to measure firstlive
- Verdict reportWeakest interface, life, assumptions, validation routelive
- Specification sheetAS9100 and NADCAP friendly wordingin validation
- Qualification reportSubstantiation package generatorin validation
- Standards taggingAPI 571, ISO 15156, ASME IX referencesin validation
- FMEA exportSeverity and occurrence pre-filledin validation
- Public scorecardBlind predictions against published outcomeslive
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
How it works
Four steps, one audit trail
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.
Verdict · case C-0412engine 0.1 · mock data
Inconel 718 built on sapphire, 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.
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
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.
Engine, liveMeasure, model, decide. Every step keeps its number.
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.