Coupled thermal-structural FEA, LCF life prediction, and transient conjugate heat transfer for aerospace hot-section and structural components. Analysis packages built for the regulatory pathway — not just the engineering question.
It's about producing a substantiation report that survives DER review. Every assumption documented. Every boundary condition justified. Every material model traceable to a qualified data source. The analysis itself might be correct — but if the documentation doesn't hold up, you're re-doing the work.
The second challenge is capability. Most stress teams are equipped for linear elastic analysis and standard fatigue checks. When the problem requires coupled transient CHT feeding into thermo-mechanical LCF, or anisotropic elasticity for single-crystal turbine blades — that's where the in-house team reaches their ceiling and the external backlog adds 4 months to the certification schedule.
Full transient CHT analysis providing the thermal field — then mapped onto a structural FE model for thermo-mechanical stress and LCF life prediction. Captures peak startup conditions that steady-state analysis cannot see. Documented to DER-acceptable standard.
Low-cycle fatigue life using Coffin-Manson with temperature-dependent material data. High-cycle endurance assessment. Goodman diagram construction for combined steady + vibratory stress. Scatter factor application per certification requirements. Applicable to turbine blades, discs, shafts, and brackets.
Creep life assessment for components under sustained high-temperature loading. Norton power-law and time-hardening models for superalloys. Creep-fatigue interaction for combined cyclic and sustained loads on hot-section components.
Linear and nonlinear static analysis documented to airworthiness standards. Includes model description, load definition, material data sources, boundary condition justification, mesh convergence data, and result interpretation. Report format structured for DER submission.
Interface stress analysis for TBC systems under thermal cycling. CTE mismatch-driven delamination prediction. Bond coat oxidation and spallation life estimation. Combined TBC + substrate + cooling channel structural assessment.
Independent review of existing FEA or CHT models before submission. We check: mesh quality at critical locations, boundary condition physical justification, material model temperature-dependence, and convergence data completeness. Written findings within 5 business days.
Every aerospace analysis deliverable is structured for submission — not internal use. The documentation standard is set by what a DER will ask for, not what's convenient to write.
A Tier-1 supplier needed to demonstrate 10,000-cycle LCF life on a redesigned CMSX-4 blade at 1,050°C / 38 bar. Steady-state analysis had predicted acceptable margins. Transient startup analysis revealed a 320°C through-wall gradient at the leading-edge cooling channel fillet — driving peak stress at a location nobody had flagged. One geometry change moved the predicted life from 8,200 to 24,000 cycles. Report accepted by engine OEM DER.
The life-limiting thermal condition in hot-section components occurs during startup — not at cruise. We run the full transient mission profile as standard. If the problem has a time-dependent thermal boundary condition, steady-state analysis is wrong by definition, and we won't submit it.
Every boundary condition has a physical justification. Every material value has a source. Every result has a mesh convergence study behind it. The report is structured to answer the questions a Designated Engineering Representative will ask — before they ask them.
CMSX-4 single-crystal elastic anisotropy. IN718 temperature-dependent plasticity and creep. Ti-6Al-4V fatigue data at cryogenic and elevated temperatures. These aren't generic material cards — they're calibrated to the actual alloy and its relevant temperature regime.
Tell us the component, the operating conditions, and the certification requirement. We'll scope the analysis and confirm whether it's achievable in your timeline — in a 30-minute call.
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