Alstom Power Inc., a wholly owned subsidiary of the General Electric Company (GE) recently completed ?Advanced Ultrasupercritical (AUSC) Materials Thick-Walled Cycling Header Development for ComTest-AUSC? under Award No. DE-FE0026183 for the U.S. Department of Energy National Energy Technology Laboratory (DOE NETL). This project developed a design for testing of a high temperature nickel-based superalloy thick-walled header to simulate cycling and flexible plant operation in new and existing plants. The objective was to simulate the expected thermal stresses of a new AUSC plant or a retrofit header in an existing plant to improve flexible dynamic operation while maintaining component integrity and overall power plant reliability. The high performance superalloy materials that enable higher operating temperatures and pressures can support future transformational power technologies including new AUSC plants at 4250-5000 psi, 730�C/760�C or will serve as a replacement component in a repowered or retrofit USC coal powered cycling plant at 3600 psi, 600�C. These alloys can also enable supercritical CO2 cycles, nuclear power, solar power and more efficient natural gas combined cycle units as targeted by the U.S. DOE/NETL Cross-Cutting Research Technology Program Plan. Recently developed advanced nickel alloys such as Inconel 740H (740H) and Haynes 282 (H282) have been successfully tested on a pilot scale for fireside corrosion using steam loop tubing at AUSC temperatures of 760�C in actual operating coal fired boiler. These high strength materials have been demonstrated their adequacy for use in other high temperature boiler components such as superheater tubes. Thick-walled superheater outlet headers which operate at high temperatures and pressure under severe cycling condition are considered as one of the most critical component in the AUSC coal fired boiler. Over the design life of a plant, these headers are exposed to the most severe fatigue and creep damage accumulation and need to be properly designed for the expected cycling in an AUSC plant with flexible operation. These materials need to demonstrate adequate design life of 20 to 30 years for creep and fatigue conditions. The following tasks were performed: 1. A conceptual design was developed of a thick-walled component representative of typical headers with several tube connections and proper flow rates (~100,000 lbs/hr) suitable for Phase II test at 760�C operation. This was based on a process analysis of expected full scale new and component retrofit designs for AUSC. 2. A multi-physics flow and heat transfer computational fluid dynamics (CFD) analysis of the component for proper layout of the header configuration, number and geometry (size) of tubes required for bypass flow, flow rates through the tubing, and sectional pressure drops was performed. Steam to header metal heat transfer film coefficients in the header section and the tubes during the two stages (half load and full load) of the cycling operation were evaluated and used in the stress analysis. 3. Detailed analytical evaluation of the thick-walled pipe and tube connections for mechanical integrity under cycling conditions was performed. This included transient thermal stress analysis and fatigue usage estimation including the tube-to-pipe weld geometries and weld materials. 4. A layout and design of the thick-walled test component was developed and instrumentation required for a test was identified. 5. Continuum Damage Mechanics (CDM) creep prediction models were extended to 740H and H282 and validated with public data on 740H and H282 for use in creep analysis. In addition, detailed creep analyses were performed separately for the design life of the conceptual AUSC superheater outlet header using these General Electric (GE) creep constitutive models. GE was the prime contractor for the project, which was directed by Principal Investigator Robert Schrecengost and Lead Scientist Dr. B. Reddy Ganta. Other collaborative participants in this project included GE Global Research, GE Boiler Engineering, and a Technical Consultant from EPRI.